Snowmobile Arctic Cat (2008 year). Manual - part 106

6-68

ZJ232

ZJ233

8. With the brake disc splines and driveshaft splines

aligned, use a soft hammer and tap the caliper

from side to side until the caliper is properly

seated to the tunnel.

9. Install the Phillips-head cap screw and lock nut

(B); then install the four lock nuts (A). Tighten to

20 ft-lb.

740-188A

10. Apply Anti-Seize Thread Compound to the

threads of the brake disc retaining nut; then install

the nut.

„NOTE: At this point, tighten the retaining nut only
until snug.

„NOTE: If the outer caliper housing was removed
during disassembling, install a new O-ring and
place the housing into position; then secure with
the two Allen-head cap screws. Tighten to 17 ft-lb.

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

MS320A

ZJ219A

11. Install the brake pads; then secure the brake pads

with the retaining pin and hairpin clip.

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

tem in this sub-section).

13. Engage the brake lever lock; then using Brake

Disc Socket Wrench, tighten the brake disc retain-

ing nut (from step 10) to 120 ft-lb.

„NOTE: The brake lever lock must be engaged for
this procedure.

MS323

„NOTE: After the retaining nut is tightened to
specifications, peen the nut at the flat spot of the
driveshaft.

6-69

6

14. Install the speedometer sensor mounting bracket to

the caliper housing with the two remaining torx-

head cap screws; then tighten to 17 ft-lb.

ZJ210A

15. Connect the harness connector to the speedometer

sensor plug-in.

16. Install the toe shield and toe hook bracket; then

install the torx-head cap screws. Tighten securely.

17. Place the expansion chamber and resonator into

position and secure with the springs and the hair-

pin clip.

18. Adjust track alignment and tension (see Section

7).

Brake Lever/Master

Cylinder Assembly

(Hydraulic System -

Bearcat 570)

REMOVING

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

bleeder valve and direct the other end into a con-

tainer. Remove the reservoir cover; then open the

bleeder valve. Allow the brake fluid to drain com-

pletely.

730-434G

2. To remove the switch, use a small screwdriver to

compress the plastic locking tabs by pushing in on

the tabs; then slide the 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.

FC258

4. Remove the two torx-head screws and clamp

securing the brake assembly to the handlebar; then

remove the assembly from the handlebar.

FC259

DISASSEMBLING

1. Remove the screw and lock nut securing the brake

lever.

! CAUTION

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

6-70

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.

AF205

INSPECTING

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

1. Inspect the screw securing the brake lever for wear

and for cracked, stretched, or damaged threads.

2. Inspect the O-ring for deterioration and distortion.

AF206

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake fluid hose for cracks, deteriora-

tion, and the condition of the fittings (threaded and

compression).

ASSEMBLING

AF207

1. Apply approved high temperature brake fluid to

the O-ring seal; then install the seal on the reser-

voir.

2. Install the reservoir on the master cylinder. Secure

with two screws.

AF205

6-71

6

3. Install the brake lever. Secure with a screw and a

new lock nut. Tighten the lock nut just to the point

of ensuring free brake lever movement.

AF202

INSTALLING

1. Position the brake assembly on the handlebar.

Secure with two torx-head machine screws and

clamp; tighten securely.

2. Install the hose on the master cylinder. Tighten

securely.

AF911D

3. Slide the brakelight switch into the brake control

until the self-locking tabs snap into position.

Lightly pull on the switch to make sure it is prop-

erly secured.

4. Bleed the brake system (see Brake System -

Hydraulic sub-section).

Brake Lever/Master

Cylinder Assembly

(ACT)

0742-152

REMOVING

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

bleeder valve and direct the other end into a con-

tainer. Remove the two torx-head screws (G)

securing the reservoir cover and remove the reser-

voir cover; then open the bleeder valve. Allow the

brake fluid to drain completely.

739-269B

2. Place an absorbent towel around the connection to

absorb brake fluid. Remove the banjo-fitting bolt

(A) securing the brake fluid hose (B) to the master

cylinder. Discard the two crush washers.

3. Remove the snap ring (C) and pin (D) securing the

brake lever to the master cylinder.

! WARNING

Do not over-tighten the lock nut. Over-tightening the
lock nut will cause the brake lever to bind. The lever
must work freely and fully return to its stop after
installation.

! WARNING

A new lock nut must be used to secure the brake
lever.

! CAUTION

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