Snowmobile Arctic Cat (2007 year). Manual - part 90

8-63

8

6. Inspect the brake hose for cracks and deteriora-

tion and check the condition of the threaded

connectors.

ASSEMBLING

736-850A

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

then install the O-ring into the groove of each

caliper 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 assem-

ble the two caliper halves. Secure with the cap

screws. Do not tighten at this time.

AF264

INSTALLING CALIPER

1. Secure the caliper assembly on the chain case

using two cap screws, lock washers, and flat

washers. Tighten the cap screws to specifica-

tions. 

AF261D

2. Install the brake hose on the caliper and tighten

securely.

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

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AF262D

3. Install the brake pads. Secure with the retaining

pin.

AF255D

AF237D

4. Bleed the brake system (see Bleeding Brake

System 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.

Brake System

(Jaguar Z1)

CHECKING BRAKE LEVER TRAVEL

1. Compress the brake lever fully.

„ NOTE: Do not pump the brake lever as it will pro-
duce an inaccurate reading.

2. Measure the distance between the brake lever

and the handlebar. The distance must be greater

than 2.54 cm (1 in.).

741-328B

3. If the distance is less than specified, check the

brake fluid level (see Checking and Adding

Brake Fluid in this sub-section), inspect for

leakage, and check the brake pads (see Check-

ing and Replacing Brake Pads in this sub-sec-

tion).

CHECKING AND ADDING BRAKE 
FLUID

1. With the fluid sight glass reservoir in a level

position, check the fluid level. The brake fluid

level must be visible in the sight glass.

„ NOTE: If the sight glass appears dark, there is a
sufficient amount of fluid in the reservoir.

! WARNING

Use only Arctic Cat approved Hi-Temp Brake Fluid
(p/n 0638-315). 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.

! WARNING

Do not operate the snowmobile if the distance
between the compressed brake lever and handlebar
is less than 2.54 cm (1 in.). Brake loss may occur.
Brake loss can result in severe personal injury.

8-65

8

741-328A

2. If the brake fluid level is not visible in the sight

glass, remove the reservoir cover and add Arctic

Cat approved brake fluid until the fluid is at the

recommended level. Install and secure the reser-

voir cover. DO NOT allow moisture to contami-

nate 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 Brake Caliper - Removing/Disas-

sembling and Assembling/Installing in this sub-sec-

tion).

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

the bleeder valve and direct the other end into a

container.

739-269B

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; 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 reservoir cover and fill the reservoir

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 brake fluid reservoir. Overfilling
the reservoir may cause the brake system to hydrau-
lically 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.

! 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.

8-66

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

the bleeder valve and direct the other end into a

container.

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; 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. 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.

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

retaining pin; then remove the pin.

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