Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 118

8-92

ZJ210A

15. Connect the harness connector to the speedometer

sensor plug-in.

16. Install the toe shield and toe hook bracket; then

install the torx-head cap screws. Tighten securely.

17. Place the expansion chamber and resonator into

position and secure with the springs and the hair-

pin clip.

18. Adjust track alignment and tension (see Section 9).

Brake Lever/Master

Cylinder Assembly

(Hydraulic System - STD)

„NOTE: If servicing the Panther 570, see Brake
Lever/Master Cylinder Assembly (ACT/Panther
570) in this section.

REMOVING

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

bleeder valve and direct the other end into a con-

tainer. Remove the reservoir cover; then open the

bleeder valve. Allow the brake fluid to drain com-

pletely.

730-434H

2. 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. Place an absorbent towel around the connection to

absorb brake fluid. Remove the brake fluid hose

from the master cylinder.

FC258

4. 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.

STD

! CAUTION

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

8-93

8

AF202

2. Remove the two screws securing the reservoir

cover; then remove the cover.

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, deteriora-

tion, and the condition of the fittings (threaded and

compression).

ASSEMBLING

AF207

1. Apply approved high temperature brake fluid to

the O-ring seal; then install the seal on the reser-

voir.

2. Install the reservoir on the master cylinder. Secure

with two screws.

AF205

8-94

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. 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 prop-

erly secured.

4. Bleed the brake system (see Brake System -

Hydraulic sub-section).

Brake Lever/Master

Cylinder Assembly

(ACT/Panther 570)

0742-152

REMOVING

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

bleeder valve and direct the other end into a con-

tainer. Remove the two torx-head screws (G)

securing the reservoir cover and remove the reser-

voir cover; then open the bleeder valve. Allow the

brake fluid to drain completely.

739-269C

! 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.

8-95

8

730-434H

2. Place an absorbent towel around the connection to

absorb brake fluid. Remove the banjo-fitting bolt

(A) securing the brake fluid hose (B) to the master

cylinder. Discard the two crush washers.

3. Remove the snap ring (C) and pin (D) securing the

brake lever to the master cylinder.

4. Using a small screwdriver, compress the tabs of

the brakelight switch (E) to release it from the

master cylinder.

5. Remove the two torx-head screws (F) and clamp

securing the brake reservoir to the handlebar; then

place a towel over the reservoir and remove the

assembly from the handlebar.

INSPECTING

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

1. Inspect the snap ring and pin securing the brake

lever for wear or damage; then inspect the brake

lever for cracks or damage.

2. Inspect the master cylinder reservoir and cover for

cracks and leakage.

„NOTE: The master cylinder is a non-serviceable
component. If any wear or damage is detected, the
master cylinder must be replaced.

3. Inspect the brake fluid hose for cracks, deteriora-

tion, and the condition of the fittings (threaded and

compression).

INSTALLING

0742-152

1. Position the brake assembly on the handlebar.

Secure with two torx-head screws (F) and clamp;

tighten securely.

2. Install the brake fluid hose (B) to the master cylin-

der with the banjo-fitting bolt (A) and two new

crush washers. Tighten securely.

3. Install the brakelight switch (E) to the master cyl-

inder.

4. Install the brake lever; then secure with pin (D)

and snap ring (C).

5. Place the reservoir cover onto the master cylinder

reservoir; then secure with the two torx-head

screws (G).

6. Bleed the brake system (see Bleeding Brake Sys-

tem in this sub-section).

Brake System

(Mechanical/Quick-Adjust)

REMOVING

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

from the brake actuator arm.

! CAUTION

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

Panther 570

! CAUTION

Always use new crush washers when installing the
brake fluid hose.