Snowmobile Arctic Cat (2007 year). Instruction - part 91

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 91

 

 

8-67

8

8. Remove the reservoir cover and remove the

remaining fluid; then fill the reservoir with fresh

fluid.

9. Pump the brake lever to ensure correct position-

ing of the brake pads; then release.

10. Fill the reservoir to the proper level with fresh

brake fluid.

„ NOTE: When new brake pads are installed, a
“burnishing” process is required. Drive the snow-
mobile slowly and compress the brake lever sev-
eral 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.

BRAKE CALIPER/BRAKE DISC/
DRIVESHAFT BEARING

Removing/Disassembling

1. Open the right-side access panel; then remove

the springs and hairpin clip securing the resona-

tor to the exhaust pipe and chassis. Remove the

resonator.

2. Remove the torx-head cap screws securing the

toe shield and hook bracket to the chassis; then

remove the shield and bracket.

3. Remove the two torx-head cap screws securing

the speedometer sensor mounting bracket to the

caliper assembly; then disconnect the harness

plug-in. Remove the sensor and bracket.

ZJ210A

4. Engage the brake lever lock; then using Brake

Disc Socket Wrench (p/n 0644-481), remove the

retaining nut from the driveshaft.

ZJ211

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

the bleeder valve and direct the other end into a

container.

739-269B

6. Open the bleeder valve and compress the brake

lever several times to drain the reservoir of

fluid.

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

absorbent towel to collect any remaining brake

fluid.

8. Disengage the brake lever lock and remove the

hairpin clip and pin securing the brake pads;

then remove both pads.

„ NOTE: If servicing the brake disc only, remove
the two remaining torx-head cap screws securing
the caliper housings together; then remove the
outside housing. Account for the O-ring.

! CAUTION

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

8-68

ZJ219A

„ NOTE: To aid in removing the inner caliper hous-
ing, completely loosen track tension.

9. Remove the four lock nuts (A) and the Phillips-

head cap screw with lock nut (B) securing the

caliper housing assembly to the chassis; then

remove the inside caliper housing along with the

brake disc from the driveshaft. Account for the

caliper spacer and the disc spacer.

740-188A

10. If the bearings are to be replaced with the caliper

housing secured in a suitable vise, drive the

outer bearing out of the housing by using a ham-

mer and sharp flat punch. Tap evenly in a criss-

cross pattern on the inner race of the bearing

until the bearing is out of the housing. Account

for the spacer.

„ NOTE: Never reuse bearings that have been
removed. Always use new bearings.

ZJ226

11. Remove the retaining ring securing the inner

bearing in the caliper housing.

ZJ245

12. If bearings are to be replaced, place the caliper

housing in a suitable clamping device; then

using a press, remove the inner bearing from the

housing.

ZJ240

„ NOTE: Never reuse bearings that have been
removed. Always use new bearings.

! CAUTION

If the caliper housings are to be separated at this
time, take care not to allow any contaminants into
the fluid passages of the calipers.

! CAUTION

Use care not to bind the bearing in the caliper hous-
ing when removing or damage to the housing may
occur.

8-69

8

„ NOTE: If the caliper housings were separated for
disassembling purposes, they must be secured
together with the small O-ring installed between
the inner and outer housings.

13. 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.

ZJ228A

„ NOTE: Remove the two remaining torx-head cap
screws securing the caliper halves. Account for
the small O-ring.

MS320A

14. Remove the pistons and O-rings; then discard

the O-rings.

ZJ229

ZJ230

ZJ251A

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, pit-

ting, scuffing, or corrosion. If any of these con-

ditions exist, replace the piston.

„ NOTE: The inner and outer caliper housings are
not serviceable components. If either or both are
defective or damaged, the complete caliper assem-
bly must be replaced. 

! WARNING

Always wear safety glasses when using compressed
air.

8-70

2. Clean the piston outer surface by using a soft

Scotch-Brite pad and clean brake fluid as a

cleaner.

AF230

3. Inspect the piston bore of the inner and outer

brake calipers for gouges, cracks, pitting, scuff-

ing, or corrosion. If any of these conditions

exist, replace the caliper.

4. Clean the caliper inner wall surface using a soft

lint-free cloth and clean brake fluid.

ZJ225A

MS320A

5. Inspect the condition of the brake pads. Replace

if damaged or worn. The brake pad thickness

must be greater than 5.0 mm (0.020 in.). If the

brake pad thickness is less than specified,

replacement of both pads is necessary.

0739-269

6. Inspect the brake hose for cracks and deteriora-

tion and check the condition of the threaded

connectors.

Assembling/Installing

0742-085

! CAUTION

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

! CAUTION

Care must be taken not to allow any contaminants
into the fluid passages of the calipers or brake sys-
tem malfunction may occur.

KEY

1. Speedometer 

Sensor

2. Screw

3. Clamp

4. Cap Screw

5. Washer

6. Mounting 

Bracket

7. Spacer

8. Caliper 

Housing - Outer

9. O-Ring

10. Clip

11. Retaining Clip

12. Retaining Nut

13. Cap Screw

14. Piston

15. O-Ring

16. Brake Pad

17. Brake Disc

18. Clip

19. Sleeve

20. Retaining Ring

21. Bearing

22. Lock Nut

23. Carriage Bolt

24. Caliper 

Housing - Inner

25. Spacer

26. Machine Screw

27. Lock Nut

28. Bearing Shield

 

 

 

 

 

 

 

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