238
DE058A
2. Using two new crush washers, connect the banjo-fit-
ting to the master cylinder; then secure with the
banjo-fitting bolt. Tighten to 20 ft-lb.
DE059A
3. Gently press the brakelight switch into the housing
(left to right) until the mounting tabs snap into the
four locating holes; then install the brake lever, pivot
pin, and snap ring.
BC206
4. Bleed the brake system (see Periodic Maintenance).
Hydraulic Brake Caliper
REMOVING/DISASSEMBLING
1. Secure the ATV on a support stand to elevate the
wheel; then remove the wheel.
2. Drain the brake fluid from the caliper, hose, and
master cylinder through the bleed screw by pumping
the brake lever/pedal.
PR235
NOTE: Whenever brake components are removed,
disassembled, or repaired where brake fluid is
exposed to air, drain all fluid and replace with new
DOT 4 brake fluid from an unopened container. Brake
fluid readily absorbs moisture from the air signifi-
cantly lowering the boiling point. This increases the
chance of vapor lock reducing braking power and
increasing stopping distance.
3. Remove the brake hose from the caliper and close
the bleed screw; then remove the caliper.
4. Compress the caliper holder against the caliper
(opposite the O-ring side) and remove the outer
brake pad; then remove the inner brake pad.
! WARNING
Arctic Cat recommends that only authorized Arctic Cat
ATV dealers perform hydraulic brake service. Failure to
properly repair brake systems can result in loss of con-
trol causing severe injury or death.
! WARNING
Make sure the ATV is solidly supported on the support
stand to avoid injury.
! WARNING
Never let brake fluid contact the eyes. Damage to the
eyes will occur. Always wear appropriate protective
safety goggles and latex gloves when handling brake
fluid.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV and do not reuse brake fluid.
