Snowmobile Arctic Cat (2004 year). Manual - part 117

8-68

AF207

1. Apply approved high temperature brake fluid to

the O-ring seal; then install the seal on the
reservoir.

2. Install the reservoir on the master cylinder. Secure

with two screws.

AF205

3. Install the brake lever. Secure with a screw and a

new lock nut. Tighten the lock nut just to the point
of ensuring free brake lever movement.

AF202

INSTALLING

1. Position the brake assembly on the handlebar.

Secure with two torx-head machine screws and
clamp; tighten securely.

2. Install the hose on the master cylinder. Tighten

securely.

AF911D

3. On standard models, slide the brakelight switch

into the brake control until the self-locking tabs
snap into position. Lightly pull on the switch to
make sure it is properly secured.

4. On models equipped with a brake lever actuated

dimmer switch, place the switch into position
beneath the master cylinder assembly making sure
the alignment pins are properly positioned; then
secure the switch with the Allen-head screw.

5. Bleed the brake system (see Brake System -

Hydraulic sub-section).

! WARNING

Do not over-tighten the lock nut. Over-tightening
the lock nut will cause the brake lever to bind. The
lever must work freely and fully return to its stop
after installation.

! WARNING

A new lock nut must be used to secure the brake
lever.

8-69

8

Brake System

(Mechanical/Quick-Adjust)

REMOVING

1. Remove the cotter pin, washer, pin, and clevis

from the brake actuator arm.

AF297D

2. Remove the recoil starter rope from the brake

cable bracket.

3. Loosen the jam nut on the brake cable and remove

the cable from the bracket.

4. Loosen and remove the two mounting cap screws

(account for the front alignment ball) and remove
the brake caliper.

AF460D

AF293D

DISASSEMBLING

1. Remove the snap ring on the stationary side of the

caliper.

AF318A

2. Remove the brake pad support plate.

AF356

3. Remove the stationary brake pad.

AF354

4. Remove the movable brake pad.

5. Remove the brake piston.

8-70

AF353

6. Remove the brake actuator arm return spring.

AF351A

7. Loosen and remove the three cap screws securing

the brake cable bracket and remove the bracket.

AF326

8. Remove the brake actuator arm assembly from the

caliper.

AF283

9. Pull out on the quick-adjust knob and turn

counterclockwise to remove.

AF328

10. Remove the adjustment bolt and spring from the

quick-adjust knob.

AF333

11. On the rear of the caliper, loosen and remove the

jam nut, washer, spring, and ball assembly.

8-71

8

AF331

CLEANING AND INSPECTING

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

1. Using a calipers, measure the stationary and

movable brake pads. The movable brake pad
thickness must exceed 12.7 mm (0.500 in.). The
stationary brake pad thickness must exceed
6.22 mm (0.245 in.).

0730-504

„ NOTE: When replacing brake pads, always
replace both pads as a set.

2. Wash all brake components with parts-cleaning

solvent and dry thoroughly.

3. Inspect all brake components for signs of wear,

fatigue, cracks, or stripped threads.

4. Inspect the spring for cracks, stretching, or

unusual bends.

5. Inspect the brake cable for any signs of fraying or

broken strands. Replace as needed.

ASSEMBLING

1. In the rear mounting hole of the caliper,

temporarily install the mounting cap screw. In
sequence, install the alignment ball (apply a small
amount of grease to the ball), spring, washer, and
jam nut. Turn the jam nut in until slight spring
pressure is felt; then remove the mounting cap
screw.

AF331

2. Apply Arctic Cat Hi-Temp Wheel Bearing Grease

(p/n 0436-094) to the actuator shaft.

AF327

3. Insert the adjustment bolt with spring and quick-

adjust knob into the actuator assembly and turn in
2 or 3 turns.

AF329

4. With the actuator shaft arm in the 11 oclock

position (located over the front mounting hole),
install the actuator shaft into the brake caliper
assembly.