Snowmobile Arctic Cat (2002 year). Instruction - part 121

8-42

AF425

4. Install the bent tab of the spring into the slot of the

adjuster socket with the outer hooked end of the

spring positioned in the clockwise direction.

AF406

5. With the spring in position, remove the cable tie

used to prevent it from unwrapping.

6. Place the O-ring seal into position; then set the end

cap into position. Make sure its tab is hooked into

the end of the spring.

AF405

7. While holding the end cap down into position,

rotate the end cap 20 turns clockwise to tension the

spring.

AF400

8. Install the three cap screws (coated with blue

Loctite #242) and tighten to 1 kg-m (7 ft-lb).

AF419

9. Apply a thin coat of grease to the spring and place

the spring into position in the end of the adjuster

bolt.

AF401

10. Use a thin coat of grease on the stem shaft to hold

it in position; then place the stem into the end of

the adjuster bolt.

8-43

8

AF418

11. Securely tighten the adjuster assembly to the chain

case.

AF417

12. Remove the set screw from the adjuster housing

and install the cap screw.

AF416

Brake System

(Hydraulic)

CHECKING BRAKE LEVER TRAVEL

1. Compress the brake lever fully.

„ NOTE: Do not pump the brake lever as it will pro-
duce an inaccurate reading.

2. Measure the distance between the brake lever and

the handlebar. The distance must be greater than

2.54 cm (1 in.).

734-505A

3. If the distance is less than specified, check the

brake fluid level (see Checking and Adding Brake

Fluid in this sub-section), inspect for leakage, and

check the brake pads (see Checking and Replacing

Brake Pads in this sub-section).

! WARNING

Use only Arctic Cat approved Hi-Temp Brake Fluid
(p/n 0638-315). Never substitute or mix different
types or grades of brake fluid. Brake loss may
occur. Brake loss can result in severe injury or even
death.

! WARNING

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

8-44

CHECKING AND ADDING BRAKE FLUID

1. With the master cylinder in a level position, check

fluid level in the reservoir. The brake fluid level

must be just below the high mark.

0734-397

2. If the brake fluid level is below the low mark,

remove the reservoir cover and add approved

brake fluid until the fluid level is just below the

high mark. 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/or whenever the brake fluid has been overheated

or contaminated. The brake fluid should be changed

every 1000 miles or at the end of the snowmobiling

season, whichever occurs first.

Arctic Cat recommends the removal and disassembly

of the brake caliper assembly when changing the brake

fluid (see Removing/Installing Caliper in this sub-sec-

tion).

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

bleeder valve and direct the other end into a

container.

0730-434

2. Slowly compress the brake lever and hold. Open

the bleeder valve to release the fluid; then

compress the brake lever repeatedly until all brake

fluid is expelled. Close the bleeder valve.

3. Add new approved brake fluid to the reservoir;

then compress the brake lever and hold. Open the

bleeder valve. Repeat the compression until brake

fluid flows free of air bubbles and appears clean.

„ NOTE: It may be necessary to refill the reservoir
a number of times to eliminate all air bubbles in
the system.

4. When the brake fluid is free of all air and the brake

lever feels firm when compressed, fill the

reservoir to a level just below the high mark; then

install and secure the cover. Remove the tube from

the bleeder valve.

5. Proceed to bleed the brake system (see Bleeding

Brake System in this sub-section).

BLEEDING BRAKE SYSTEM

If the brake lever feels spongy when applied, the brake

system may need to be bled. To bleed the brake sys-

tem, use the following procedure.

1. Remove the master cylinder reservoir cover and

fill the reservoir to the high mark with approved

brake fluid.

! CAUTION

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

! WARNING

Do not overfill the master cylinder reservoir. Over-
filling the reservoir may cause the brake system to
hydraulically lock. Use only approved brake fluid.
Never substitute or mix different types or grades of
brake fluid. Brake loss may occur. Brake loss can
result in severe injury or even death.

! 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 sub-
stitute may result in a loss of brakes.

! CAUTION

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

! WARNING

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

8-45

8

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

bleeder valve and direct the other end into a

container.

0730-434

3. Slowly compress the brake lever and hold. Open

the bleeder valve to release the fluid and air. When

the fluid stops flowing, 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

reservoir to a level just below the high mark; then

install and secure the cover. Remove the tube from

the bleeder valve.

CHECKING AND REPLACING 

BRAKE PADS

To check and replace the brake pads, use the following

procedure.

1. Measure the thickness of both brake pads. 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.

0730-434

2. Remove the retaining pin securing the brake pads

to the caliper assembly.

3. Pull both brake pads out of the caliper assembly.

AF255D

4. Using a large screwdriver, slowly push both brake

pistons into the caliper.

5. Position the new brake pads into the caliper and

secure with the retaining pin.

„ 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.

AF255D

! WARNING

Do not use brake fluid from a container that has
been opened for a long period of time. Unsealed
brake fluid containers will absorb moisture and can
contaminate the fluid inside.

! CAUTION

Care must be taken not to pry against the brake
disc when pushing on the pistons or severe
damage may occur.