Snowmobile Arctic Cat (2009 year). Manual - part 15

MAINTENANCE

53

Once which fuse to check has been

determined, perform the following

steps:

1. Open the right-side access panel;

then on 4-stroke models, remove

the fuse panel cover (the fuse

panel is located behind the bat-

tery). On 2-stroke models, discon-

nect the fuse connector harness.

ZJ005A

ZJ306A

 NOTE: On 4-stroke models, there
are spare fuses inside the fuse
panel.

2. Remove the suspected fuse.

3. Look through the clear side of the

fuse to see if the metal wire inside

is separated. If it is, the fuse is

blown and should be replaced with

a fuse of the correct amperage rat-

ing.

4. Install the fuse panel cover.

Even after replacing a fuse, it may con-

tinue to blow if the cause of the over-

load is not determined. If the fuse

continues to blow, take the snowmobile

to an authorized Arctic Cat Snowmo-

bile dealer for service. If not under

warranty, this service is at the discre-

tion and expense of the snowmobile

owner.

HYDRAULIC BRAKE 

SYSTEM

Arctic Cat recommends that the brake

system (brake lever, fluid reservoir,

hose, caliper, pads, and brake disc) be

checked daily for fluid leakage, wear,

or damage and for proper operation.

Also, the brake fluid level must be

checked every time before starting the

engine. The brake fluid must be visible

in the sight glass.

Checking/Adding 

Brake Fluid

1. With sight glass reservoir in a

level position, check the fluid

level. The brake fluid level must

be visible in the sight glass.

 NOTE: If the sight glass appears
dark, there is a sufficient amount
of fluid in the reservoir.

! WARNING

Always replace a fuse with one
having the same specified amper-
age rating. Using a fuse with a
higher rating can cause severe
wire damage and could start a fire.

! WARNING

DO NOT operate the snowmobile
when the brake lever lock is
engaged or when any component
in the brake system is damaged,
worn, or adjusted improperly. If the
snowmobile is operated and the
brake system is not functioning
properly, severe personal injury
could result.

54

MAINTENANCE

741-328A

2. If the brake fluid is not visible in

the sight glass, remove the reser-

voir cover and add Arctic Cat

approved brake fluid until the fluid

is at the recommended level.

Install and secure the reservoir

cover. Do not allow moisture to

contaminate the brake system.

Changing Brake Fluid

The brake fluid must be changed on a

regular basis and whenever the brake

fluid has been overheated or contami-

nated. The brake fluid should be

changed every 1000 miles or at the end

of the snowmobiling season, which-

ever occurs first. Take the snowmobile

to an authorized Arctic Cat Snowmo-

bile dealer for this service. This service

is at the discretion and expense of the

snowmobile owner.

Checking Brake Lever 

Travel

Before each use, check the brake lever

travel using the following procedure:

1. Compress the brake lever fully.

 NOTE: Do not pump the brake
lever as it will produce an inaccu-
rate reading.

2. Measure the distance between the

brake lever and the handlebar. The

distance must be greater than 2.54

cm (1 in.).

741-328B

3. If the resultant distance is less than

specified, take the snowmobile to

an authorized Arctic Cat Snowmo-

bile dealer for service. If not under

warranty, this service is at the dis-

cretion and expense of the snow-

mobile owner.

Bleeding Brake System

If the brake lever feels spongy when

applied, the brake system may need to

be bled. To bleed the brake, use the fol-

lowing procedure:

! CAUTION

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

! WARNING

Do not overfill the brake fluid res-
ervoir. Overfilling the reservoir
may cause the brake system to
hydraulically lock. Use only Arctic
Cat approved brake fluid. Never
substitute or mix different types or
grades of brake fluid. Brake loss
can result. Brake loss can result in
severe injury or even death.

! WARNING

Do not operate the snowmobile if
the compressed distance between
the brake lever and the handlebar
is less than 2.54 cm (1 in.). Brake
loss may occur. Brake loss can
result in severe personal injury.

MAINTENANCE

55

 NOTE: The brake system may be
bled by the snowmobile owner if
qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arc-
tic Cat Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.

1. Remove the reservoir cover and

fill the reservoir with Arctic Cat

approved brake fluid.

2. Slide a piece of flexible tubing

over the ball of the bleeder valve

and direct the other end into a con-

tainer.

739-269B

3. Slowly compress the brake lever

and hold. Open the bleeder valve

to release the fluid and air. When

the fluid stops, close the bleeder

valve; then release the brake lever.

4. Repeat step 3 until the brake fluid

flows free of air bubbles.

 NOTE: It may be necessary to
refill the reservoir during the
bleeding process.

5. When the brake fluid is free of all

air and the brake lever feels firm

when compressed, fill the reser-

voir; then install and secure the

cover. Remove the tube from the

bleeder valve.

Checking/Changing 

Brake Pads

The condition of the brake pads must

be checked daily and changed if worn

or damaged. To check and change the

brake pads, use the following proce-

dure:

 NOTE: The brake pads may be
changed by the snowmobile owner
if qualified to do so. If the owner
does not feel qualified, take the
snowmobile to an authorized Arc-
tic Cat Snowmobile dealer for this
service. This service is at the dis-
cretion and expense of the snow-
mobile owner.

 NOTE: When installing new
brake pads, always install them as
a set. Never install just one pad or
use brake pads which have been
used in another snowmobile.

1. Measure the thickness of both

brake pads. The brake pad thick-

ness must be greater than 5.0 mm

(0.20 in.). If the brake pad thick-

ness is less than specified, replace-

ment of both pads is necessary.

0739-269

2. Remove the pin/hairpin clip secur-

ing the brake pads to the caliper

assembly.

! CAUTION

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

! WARNING

Use only Arctic Cat approved
brake fluid. Any substitute may
result in a loss of brakes.

56

MAINTENANCE

3. Remove the brake fluid reservoir

cover; then remove most of the

brake fluid from the reservoir.

Install the cover.

 NOTE: The above procedure will
allow room for the fluid from the
caliper when the pistons are
pushed into the caliper for install-
ing new brake pads. Replacing the
cover will prevent fluid spillage.

4. Using a pair of pliers, pull one

brake pad out of the caliper assem-

bly.

 NOTE: Changing one pad at a
time will prevent one piston from
pushing out the other piston from
the caliper.

5. Using a flat-blade tool, slowly and

carefully push the piston into the

caliper.

6. Position the new brake pads into

the caliper.

7. Repeat steps 4-6 for the other pad;

then secure the pads with the pin/

hairpin clip.

8. Remove the reservoir cover and

remove the remaining fluid; then

fill the reservoir with fresh fluid

and install the cover.

9. Pump the brake lever to ensure

correct positioning of the brake

pads; then release.

10. Remove the reservoir cover and

fill the reservoir to the proper level

with fresh brake fluid; then install

the cover.

 NOTE: When new brake pads are
installed, a “burnishing” process
is required. Drive the snowmobile
slowly and compress the brake
lever several times until the pads
just start to warm up; then allow
them to cool down. This procedure
stabilizes the pad material and
extends the life of the pads.

DRIVE BELT

The drive belt transfers power from the

drive clutch to the driven pulley. If the

belt is worn, cracked, or stretched,

maximum power will not be transmit-

ted and the belt could also fail and

therefore must be replaced. Periodic

checks (at least once a month under

normal usage) of two drive belt specifi-

cations are essential.

1. Measure the outside circumference

of the drive belt. The belt should

be within the recommended range

in circumference.

2. Measure the outside width of the

drive belt. The belt should be within

the recommended range in width.

3. Check the belt for cracking, fray-

ing, etc.

If any of the specifications or condi-

tions are unsatisfactory, replace the

drive belt.

 NOTE: Drive belts should be pur-
chased from an authorized Arctic
Cat Snowmobile dealer, as Arctic
Cat drive belts are made to exact
specifications and of quality mate-
rial. Belts made by other manufac-
turers may not be of the same
specifications or quality and,
therefore, usage could result in
poor performance and premature
belt failure.

Before starting the snowmobile in

extremely cold temperatures, the drive

belt should be removed and warmed up

to room temperature. Once the drive

belt is at room temperature, install the

drive belt.

! CAUTION

Never run the engine with the drive
belt removed. Excessive revving of
the engine could result in serious
engine damage and drive clutch
failure.