Snowmobile Arctic Cat (2008 year). Manual - part 105

6-64

ZJ226

11. Remove the retaining ring securing the inner bear-

ing 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.

„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 pis-

tons.

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

! CAUTION

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

! WARNING

Always wear safety glasses when using compressed
air.

6-65

6

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 condi-

tions 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. 

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, scuffing, 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 (0.20 in.). If the brake pad

thickness is less than specified, replacement of

both pads is necessary.

! 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.

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0739-269

6. Inspect the brake hose for cracks and deterioration

and check the condition of the threaded connec-

tors.

Assembling/Installing

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

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

per half.

ZJ231

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

the brake piston; then while twisting, install the

piston with the dished side facing out.

ZJ229

ZJ230

„NOTE: To aid in installing the piston, make sure
the piston O-ring is properly seated in the groove
of the caliper housing.

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

the two caliper halves. Secure with the two torx-

head cap screws. Tighten only until snug.

ZJ231A

„NOTE: Always use a new O-ring and make sure
the O-ring is properly seated in the outer brake
housing.

MS320A

4. Using a suitable press, install a new inner bearing

into the caliper housing until it is properly seated.

! CAUTION

Never reuse piston O-rings. Always install new O-
rings when installing pistons in the brake caliper.

6-67

6

ZJ241

ZJ239A

5. Install the snap ring securing the inner bearing in

the caliper housing.

ZJ245

6. Install the bearing spacer; then press a new outer

bearing into the caliper housing until it is properly

seated.

ZJ244

„NOTE: For aid in installing the outer bearing, it is
advisable to insert a length of shaft (the same
diameter as the bearing inner bore) through the
inner bearing, spacer, and outer bearing to main-
tain proper alignment of the spacer for driveshaft
installation.

ZJ242

ZJ243

7. Apply Anti-Seize Thread Compound to the splines

of the brake disc; then with the brake caliper

spacer properly installed, slide the caliper onto the

driveshaft far enough to install the spacer and

brake disc.

! CAUTION

When installing a bearing, always press on the outer
race of the bearing.

! CAUTION

When installing a bearing, always press on the outer
race of the bearing.