Snowmobile Arctic Cat (2004 year). Manual - part 116

8-64

2. Clean the piston outer surface by using a Scotch-

Brite pad and clean brake fluid as a cleaner.

AF230

3. Inspect the brake caliper for gouges, cracks,

pitting, scuffing, or corrosion. If any of these
conditions exist, replace the caliper.

4. Clean the caliper inner wall surface using a soft

Scotch-Brite pad and clean brake fluid. Wipe
caliper wall clean with a clean rag and brake fluid.

AF267

5. Inspect the condition of the brake pads. Replace if

damaged or worn. The brake pad thickness must
be greater than 3.2 mm (0.125 in.). If the brake
pad thickness is less than specified, replacement of
both pads is necessary.

6. Inspect the brake hose for cracks and deterioration

and check the condition of the threaded
connectors.

ASSEMBLING

736-850A

1. Apply approved brake fluid to the new O-ring;

then install the O-ring into the groove of each
caliper half.

AF251

„ NOTE: Always use a new O-ring when assem-
bling the brake caliper.

2. In each caliper half, apply approved brake fluid to

the brake piston; then while twisting, install the
piston with the open side facing out.

AF266

! CAUTION

Do not use any sharp cleaning tool on the piston
surface as it may cause damage. Parts-cleaning
solvent must not be used as it can damage the
piston O-ring.

KEY

1. Retaining Pin
2. Cap Screw
3. Washer
4. Brake Caliper Assy
5. Housing O-Ring
6. O-Ring
7. Piston

8. Bleed Screw
9. Brake Pad Set

10. Housing
11. Housing
12. Cap Screw
13. Lock Washer
14. Washer

8-65

8

AF269

3. Place the small O-ring into position; then assemble

the two caliper halves. Secure with the cap screws.
Do not tighten at this time.

AF264

INSTALLING CALIPER

1. Secure the caliper assembly on the chain case

using two cap screws, lock washers, and flat
washers. Tighten the cap screws to 4.2 kg-m
(30 ft-lb). Tighten the upper cap screws to 5 kg-m
(36 ft-lb).

AF261D

2. Install the brake hose on the caliper and tighten

securely.

AF262D

3. Install the brake pads. Secure with the retaining

pin.

AF255D

AF237D

4. Bleed the brake system (see Bleeding Brake

System in this sub-section).

„ NOTE: If new brake pads were installed, a bur-
nishing process is required. Drive the snowmobile
slowly and compress the brake lever repeatedly
until the pads just start to heat up; then allow them
to cool down. This process stabilizes the pad
material and extends the life of the pads.

8-66

Brake Lever/Master

Cylinder Assembly

(Hydraulic System)

REMOVING

1. Slide a piece of flexible tubing over the ball of the

bleeder valve and direct the other end into a
container. Remove the reservoir cover; then open
the bleeder valve. Allow the brake fluid to drain
completely.

0730-434

2. On standard models to remove the switch, use a

small screwdriver to compress the plastic locking
tabs by pushing in on the tabs; then slide the
switch free of the brake control. 

AF201D

3. On models equipped with a brake lever actuated

dimmer switch to remove the switch, remove the
Allen-head cap screw from beneath the master
cylinder and free the switch from the master
cylinder assembly.

4. Place an absorbent towel around the connection to

absorb brake fluid. Remove the brake fluid hose
from the master cylinder.

FC258

5. Remove the two torx-head screws and clamp

securing the brake assembly to the handlebar; then
remove the assembly from the handlebar.

FC259

DISASSEMBLING

1. Remove the screw and lock nut securing the brake

lever.

AF202

2. Remove the two screws securing the reservoir

cover; then remove the cover.

! CAUTION

Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the snowmobile.

8-67

8

AF204

3. Remove the two screws securing the reservoir to

the master cylinder.

4. Compress the locking tabs of the reservoir and

remove the reservoir from the master cylinder.
Account for an O-ring seal.

AF205

INSPECTING

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Inspect the screw securing the brake lever for wear

and for cracked, stretched, or damaged threads.

2. Inspect the O-ring for deterioration and distortion.

AF206

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake fluid hose for cracks,

deterioration, and the condition of the fittings
(threaded and compression).

ASSEMBLING

0736-650

0738-179

KEY

1. Brake Assy
2. Brake Lever
3. Lever Mounting 

Screw

4. Lock Nut
5. Reservoir
6. Gasket
7. Cover
8. Screw

9. Machine Screw

10. O-Ring
11. Master Cylinder
12. Lock Washer
13. Screw
14. Clamp
15. Dimmer Control 

Assy

16. Dimmer Control 

Housing

17. Switch Assy
18. Dimmer Knob
19. Handwarmer 

Switch

20. Cover Plate
21. Self-Tapping 

Screw

22. Brakeline
23. Adapter Fitting

KEY

1. Brake Assy
2. Brake Lever
3. Lever Mounting 

Screw

4. Lock Nut
5. Reservoir
6. Gasket

7. Cover
8. Screw
9. Machine Screw

10. O-Ring
11. Master Cylinder
12. Lock Washer

13. Screw
14. Clamp
15. Brakelight/Dim-

mer Switch

16. Spring Assy
17. Brakeline