Snowmobile Arctic Cat (2007 year). Manual - part 89

8-59

8

CHECKING AND ADDING BRAKE 
FLUID

1. With the master cylinder in a level position,

check fluid level in the reservoir. The brake

fluid level must be just below the high mark.

0734-397

2. If the brake fluid level is below the low mark,

remove the reservoir cover and add approved

brake fluid until the fluid level is just below the

high mark. Install and secure the reservoir cover.

DO NOT allow moisture to contaminate the

brake system.

CHANGING BRAKE FLUID

The brake fluid must be changed on a regular basis

and/or whenever the brake fluid has been over-

heated or contaminated. The brake fluid should be

changed every 1000 miles or at the end of the snow-

mobiling season, whichever occurs first.

Arctic Cat recommends the removal and disassem-

bly of the brake caliper assembly when changing the

brake fluid (see Removing/Installing Caliper in this

sub-section).

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

the bleeder valve and direct the other end into a

container.

730-434A

2. Slowly compress the brake lever and hold. Open

the bleeder valve to release the fluid; then com-

press the brake lever repeatedly until all brake

fluid is expelled. Close the bleeder valve.

3. Add new approved brake fluid to the reservoir;

then compress the brake lever and hold. Open

the bleeder valve. Repeat the compression until

brake fluid flows free of air bubbles and appears

clean.

„ NOTE: It may be necessary to refill the reservoir
a number of times to eliminate all air bubbles in
the system.

4. When the brake fluid is free of all air and the

brake lever feels firm when compressed, fill the

reservoir to a level just below the high mark;

then install and secure the cover. Remove the

tube from the bleeder valve.

5. Proceed to bleed the brake system (see Bleeding

Brake System in this sub-section).

BLEEDING BRAKE SYSTEM

If the brake lever feels spongy when applied, the

brake system may need to be bled. To bleed the

brake system, use the following procedure.

1. Remove the master cylinder reservoir cover and

fill the reservoir to the high mark with approved

brake fluid.

! CAUTION

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

! WARNING

Do not overfill the master cylinder reservoir. Overfill-
ing the reservoir may cause the brake system to
hydraulically lock. Use only approved brake fluid.
Never substitute or mix different types or grades of
brake fluid. Brake loss may occur. Brake loss can
result in severe injury or even death.

! CAUTION

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

! WARNING

Use only Arctic Cat approved brake fluid. Any sub-
stitute may result in a loss of brakes.

8-60

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

the bleeder valve and direct the other end into a

container.

730-434A

3. Slowly compress the brake lever and hold. Open

the bleeder valve to release the fluid and air.

When the fluid stops flowing, close the bleeder

valve; then release the brake lever.

4. Repeat step 3 until the brake fluid flows free of

air bubbles.

„ NOTE: It may be necessary to refill the reservoir
during the bleeding process.

5. When the brake fluid is free of all air and the

brake lever feels firm when compressed, fill the

reservoir to a level just below the high mark;

then install and secure the cover. Remove the

tube from the bleeder valve.

CHECKING AND REPLACING 
BRAKE PADS

To check and replace the brake pads, use the follow-

ing procedure.

1. Measure the thickness of both brake pads. 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.

0730-434

2. Remove the retaining pin securing the brake

pads to the caliper assembly.

MS484

3. Remove the brake fluid reservoir cover; then

remove most of the brake fluid from the reser-

voir. 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.

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

the caliper assembly.

MS485

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

! CAUTION

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

! WARNING

Use only approved brake fluid. Any substitute may
result in a loss of brakes.

! WARNING

Do not use brake fluid from a container that has
been opened for a long period of time. Unsealed
brake fluid containers will absorb moisture and can
contaminate the fluid inside.

8-61

8

5. Using a flat-blade tool, slowly and carefully

push the piston into the caliper.

6. Position the new brake pad into the caliper.

„ 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.

MS485

7. Repeat steps 4-6 for the other pad; then secure

the pads with the pin.

8. Remove the reservoir cover and remove the

remaining fluid; then fill the reservoir with fresh

fluid.

9. Compress the brake lever repeatedly 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 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.

11. Bleed the brake system (see Bleeding Brake

System in this sub-section).

REMOVING CALIPER

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

the bleeder valve and direct the other end into a

container.

730-434A

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 cali-

per halves; then remove the two cap screws,

lock washers, and flat washers securing the

brake caliper to the chain case.

! CAUTION

Care must be taken not to pry against the brake disc
when pushing on the pistons or severe damage may
occur.

! CAUTION

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

8-62

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

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, pit-

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

ditions 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, pit-

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

ditions exist, replace the caliper.

4. Clean the caliper inner wall surface using a soft

Scotch-Brite pad and clean brake fluid. Wipe cal-

iper 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.

! WARNING

Always wear safety glasses when using compressed
air.

! CAUTION

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