Snowmobile Arctic Cat (2002 year). Instruction - part 122

8-46

6. Compress the brake lever repeatedly to ensure

correct positioning of the brake pads; then release.

„ NOTE: When new brake pads are installed, a bur-
nishing 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 stabilizes the pad
material and extends the life of the pads.

REMOVING CALIPER

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. Open the bleeder valve and compress the brake

lever several times to drain the reservoir of fluid.

3. Remove the brake hose from the caliper. Use an

absorbent towel to collect any remaining brake

fluid.

AF262D

4. Remove the retaining pin securing the brake pads

to the caliper assembly; then remove the brake

pads.

AF255D

5. Loosen the upper cap screws securing the caliper

halves; then remove the two cap screws, lock

washers, and flat washers securing the brake

caliper to the chain case.

AF261D

6. Remove the caliper assembly from the engine

compartment.

DISASSEMBLING

1. Position a piece of wood between the pistons.

Using low-pressure compressed air, blow into the

caliper brake hose fitting to remove the brake

pistons.

AF248

! CAUTION

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

! WARNING

Always wear safety glasses when using com-
pressed air.

8-47

8

2. Remove the two cap screws securing the caliper

halves. Account for the small O-ring.

3. Remove the piston O-rings and discard.

AF264

CLEANING AND INSPECTING

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

1. Inspect the brake pistons for gouges, cracks,

pitting, scuffing, or corrosion. If any of these

conditions exist, replace the piston.

2. Clean the piston outer surface by using a Scotch-

Brite pad and clean brake fluid as a cleaner.

AF230

3. Inspect the brake caliper for gouges, cracks,

pitting, scuffing, or corrosion. If any of these

conditions exist, replace the caliper.

4. Clean the caliper inner wall surface using a soft

Scotch-Brite pad and clean brake fluid. Wipe

caliper wall clean with a clean rag and brake fluid.

AF267

5. Inspect the condition of the brake pads. Replace if

damaged or worn. 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.

6. Inspect the brake hose for cracks and deterioration

and check the condition of the threaded

connectors.

ASSEMBLING

736-850A

1. Apply approved brake fluid to the new O-ring;

then install the O-ring into the groove of each

caliper half.

AF251

„ NOTE: Always use a new O-ring when assem-
bling the brake caliper.

! CAUTION

Do not use any sharp cleaning tool on the piston
surface as it may cause damage. Parts-cleaning
solvent must not be used as it can damage the
piston O-ring.

KEY

1. Retaining Pin
2. Cap Screw
3. Washer
4. Brake Caliper Assy
5. Housing O-Ring
6. O-Ring
7. Piston

8. Bleed Screw
9. Brake Pad Set

10. Housing
11. Housing
12. Cap Screw
13. Lock Washer
14. Washer

8-48

2. In each caliper half, apply approved brake fluid to

the brake piston; then while twisting, install the

piston with the open side facing out.

AF266

AF269

3. Place the small O-ring into position; then assemble

the two caliper halves. Secure with the cap screws.

Do not tighten at this time.

AF264

INSTALLING CALIPER

1. Secure the caliper assembly on the chain case

using two cap screws, lock washers, and flat

washers. Tighten the cap screws to 4.2 kg-m

(30 ft-lb). Tighten the upper cap screws to 5 kg-m

(36 ft-lb).

AF261D

2. Install the brake hose on the caliper and tighten

securely.

AF262D

3. Install the brake pads. Secure with the retaining

pin.

AF255D

AF237D

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8

4. Bleed the brake system (see Bleeding Brake

System in this sub-section).

„ NOTE: If new brake pads were installed, a bur-
nishing 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 stabilizes the pad
material and extends the life of the pads.

Brake Lever/Master

Cylinder Assembly

(Hydraulic System)

REMOVING

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

bleeder valve and direct the other end into a

container. Remove the reservoir cover; then open

the bleeder valve. Allow the brake fluid to drain

completely.

0730-434

2. Using a small screwdriver, push in on the self-

locking tab; then slide the brakelight 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.

4. Remove the two torx-head screws and clamp

securing the brake assembly to the handlebar; then

remove the assembly from the handlebar.

DISASSEMBLING

1. Remove the screw and lock nut securing the brake

lever.

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.

! CAUTION

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