Snowmobile Arctic Cat (2008 year). Manual - part 104

6-60

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 connec-

tors.

Assembling

736-850A

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

then install the O-ring into the groove of each cali-

per half.

AF251

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

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 (STD)

1. Secure the caliper assembly on the chain case

using two cap screws, lock washers, and flat wash-

ers. Tighten the cap screws to 30 ft-lb. Tighten the

upper cap screws to 36 ft-lb.

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

6-61

6

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

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

tem 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.

CHECKING AND REPLACING 
BRAKE PADS (ACT)

To check and replace the brake pads, use the following

procedure.

1. Remove the brake fluid reservoir cover; then

remove most of the brake fluid from the reservoir.

Replace the cover.

„NOTE: The above procedure will allow room for
the fluid from the caliper when the pistons are
pushed into the caliper for installing new brake
pads. Replacing the cover will prevent fluid spill-
age.

2. Open the right-side access panel and remove the

springs and hairpin clip securing the resonator;

then remove it from the engine compartment.

„NOTE: Measure the thickness of both brake
pads. The brake pad thickness must be greater
than 5.0 mm (0.20 in.). If the brake pad thickness is
less than specified, replacement of both pads is
necessary.

0739-269

3. Remove the hairpin clip from the brake pad retain-

ing pin; then remove the pin.

6-62

ZJ222

„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.

4. Using a pair of pliers, pull one brake pad out of the

caliper assembly.

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

ZJ224

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 and hairpin clip.

ZJ223

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 positioning

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 (ACT)

Removing/Disassembling

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

springs and hairpin clip securing the resonator to

the exhaust pipe and chassis. Remove the resona-

tor.

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 cali-

per 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, remove the retaining nut

from the driveshaft.

6-63

6

ZJ211

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

bleeder valve and direct the other end into a con-

tainer.

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.

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 cali-

per 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 hammer and

sharp flat punch. Tap evenly in a crisscross 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.

! CAUTION

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

! 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.