Snowmobile Arctic Cat (2004 year). Manual - part 118

8-72

AF338

5. Place the brake cable bracket and rope guide into

position and secure with the three cap screws and
lock washers.

AF352A

6. Install the brake arm actuator return spring.

AF351A

7. Install the brake piston making sure that the slot in

the piston aligns with the roll pin in the caliper.

AF325A

8. Install the movable (thick) brake pad into the

caliper making sure that the slot in the pad aligns
with the roll pin in the caliper.

AF320

9. Install the snap ring into the caliper making sure

that the sharp edge of the snap ring faces out and
the opening faces down.

AF318A

10. Install the brake pad support plate with the large

tab located in the opening of the snap ring.

! WARNING

Be sure the snap ring is fully seated. Personal
injury may result if the snap ring isnt seated prop-
erly within the slot of the caliper.

8-73

8

AF322

11. Install the stationary (thin) brake pad into the

caliper making sure the slot in the pad aligns with
the small tab on the support plate. Use a rubber
band to hold the pad and plate in position.

INSTALLING

1. With the rubber band holding the stationary pad

and support plate in position, install the caliper
assembly over the brake disc. Remove the rubber
band.

AF321A

2. Apply green Loctite #609 to the rear mounting cap

screw with washer and install. DO NOT
TIGHTEN AT THIS TIME.

AF460D

3. Apply a small amount of grease to the alignment

ball and install into the front of the caliper. Apply
blue Loctite #243 to the front cap screw with
washer; then install and tighten both cap screws to
6.9 kg-m  (50 ft-lb).

AF293D

AF458D

4. Place the brake cable into the rear slot of the brake

cable bracket and tighten securely.

AF462D

5. Insert the cable end into the rear slot of the clevis.

Install the pin through the clevis and actuator arm;
then install the washer. Install a new cotter pin into
the clevis pin and spread the cotter pin.

! CAUTION

Make sure that the brake pads are properly
positioned in the caliper or damage to the brake
system will result.

8-74

AF340

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

clockwise until there is 6-13 mm (1/4-1/2 in.) free-
play at the brake lever.

0727-451

7. Set the brake lever lock; then securely tighten the

jam nut on the upper mounting cap screw.

AF298

8. Release the brake  lever lock and recheck the

brake lever free-play (adjust as needed); then place
the recoil starter rope into the guide portion of the
brake cable bracket.

ADJUSTING BRAKE LEVER TRAVEL

1. Rotate the brake disc alternately forward and

backward while slowly compressing the brake
lever.

2. At the point where the disc is locked, check the

distance between the brake lever and lever stop.
The distance must be within a range of 6-13 mm
(1/4-1/2 in.).

0727-451

3. To decrease brake lever travel (set up brake), pull

out on the spring-loaded quick-adjust knob and
rotate the knob clockwise periodically checking
the brake lever travel distance until the correct
travel distance is attained. Once the correct brake
lever travel has been obtained, release the knob
into a secured position.

„ NOTE: If the quick-adjust knob has reached its
maximum adjustment (cannot be rotated any fur-
t h e r   c l o c k w i s e ) ,   b o t h   b r a k e   p a d s   m u s t   b e
replaced.

0730-151

! WARNING

Before making any adjustment, make certain the
brake quick-adjust knob isnt hot. If the snowmobile
has just been used, allow some time for the knob to
cool or burns may result.

! WARNING

DO NOT attempt to adjust the brake with the flange
nuts on the brake cable bracket. Incorrect brake
adjustment may occur causing possible brake fail-
ure.

8-75

8

4. To increase brake lever travel (loosen the brake),

pull out on the quick-adjust knob and rotate the
knob counterclockwise periodically checking the
brake lever travel. Once the desired brake lever
travel is obtained, release the knob into a secured
position.

REPLACING BRAKE PADS

1. Using a 1/2-in. socket, remove the front brake

assembly guide pin. Slowly pull the pin from the
assembly and catch the alignment ball as it drops
from the hole in the front of the caliper assembly.

2. Remove the rear guide pin; then slide the brake

caliper assembly forward free of the brake disc.

3. Remove the stationary brake pad from the caliper

assembly.

4. Tip the caliper on its side and allow the movable

brake pad to drop free of the caliper assembly.

5. Place the new movable brake pad into position;

then temporarily secure with a rubber band to hold
it in place.

6. With the backing plate in position (wide tab

positioned between the snap ring ears), install the
stationary brake pad making sure the notch in the
pad is aligned with small tab of the backing plate.
Using a rubber band, temporarily secure the pad.

7. Place the brake assembly back into position over

the brake disc. Apply green Loctite #609 to the
rear guide pin; then install the rear guide pin.

8. Insert the alignment ball into the hole at the front

of the caliper, apply green Loctite #609 to the
front guide pin, and install the front guide pin.
Tighten the two alignment pins to 4.2 kg-m
(30 ft-lb). Cut and remove the two rubber bands.

„ NOTE: When new brake pads have been
installed, a burnishing 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 stabi-
lizes the pad material and extends the life of the
pads.

Brake Control

(Mechanical/Quick-Adjust)

REMOVING AND DISASSEMBLING

1. Remove the Phillips-head screws securing the

handlebar pad to the handlebar.

AL136D

2. Remove the retaining ring, washer, and pin

securing the brake lever.

AL137D

AL138D

3. Loosen the jam nut securing the brake cable to the

brake cable bracket.

! CAUTION

The brake pads must be replaced as a set. Do not
under any circumstances ever replace only one
of the brake pads.