Snowmobile Arctic Cat (2007 year). Manual - part 92

8-71

8

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

then install the O-ring into the groove of each

caliper 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 assem-

ble 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 bear-

ing into the caliper housing until it is properly

seated.

ZJ241

! CAUTION

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

! CAUTION

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

8-72

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 prop-

erly 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 for the spacer for driveshaft
installation.

ZJ242

ZJ243

7. Apply Anti-Seize Thread Compound (p/n 0678-

146) 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.

ZJ232

ZJ233

! CAUTION

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

8-73

8

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 prop-

erly seated to the tunnel.

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

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

to specifications.

740-188A

10. Apply Anti-Seize Thread Compound (p/n 0678-

146) 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 specifi-
cations.

„ 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

System in this sub-section).

13. Engage the brake lever lock; then using Brake

Disc Socket Wrench (p/n 0644-481), tighten the

brake disc retaining nut (from step 10) to speci-

fications.

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

MS323

14. Install the speedometer sensor mounting bracket

to the caliper housing with the two remaining

torx-head cap screws; then tighten to specifica-

tions.

ZJ210A

15. Connect the harness connector to the speedome-

ter sensor plug-in.

8-74

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

hairpin clip.

18. Adjust track alignment and tension (see Section

9).

Brake Lever/Master

Cylinder Assembly

(660 cc/1100 cc Z1)

0742-152

REMOVING

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

the bleeder valve and direct the other end into a

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

securing the reservoir cover and remove the res-

ervoir cover; then open the bleeder valve. Allow

the brake fluid to drain completely.

730-434G

739-269C

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.

4. Using a small screwdriver, compress the tabs of

the brakelight switch (E) to release it from the

master cylinder.

5. Remove the two torx-head screws (F) and clamp

securing the brake reservoir to the handlebar;

then place a towel over the reservoir and remove

the assembly from the handlebar.

INSPECTING

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

1. Inspect the snap ring and pin securing the brake

lever for wear or damage; then inspect the brake

lever for cracks or damage.

AF206

2. Inspect the master cylinder reservoir and cover

for cracks and leakage.

! CAUTION

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