37
1. Remove the brake fluid reservoir cover;
then remove most of the brake fluid
from the reservoir. Install the cover.
NOTE: The above procedure will
allow room for the fluid from the cali-
per when the pistons are pushed
into the caliper for installing new
brake pads. Replacing the cover will
prevent fluid spillage.
2. Open the left-side access panel.
3. Remove the torx-head screws secur-
ing the brake shield to the belt guard
mount; then remove the cap screws
securing the brake shield to the
brake caliper.
4. Carefully move the shield out of the
way; then remove the hairpin clip
securing the brake pads to the cali-
per assembly.
5. Using a pair of pliers, pull the outer
brake pad out of the caliper assembly.
PC013
NOTE: Changing one pad at a time
will prevent one piston from pushing
out the other piston from the caliper.
6. Measure the thickness of the brake
pad. 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.
PC011A
7. Using a flat-blade tool, slowly and
carefully push the piston into the
caliper.
8. Position the outer brake pad into the
caliper; then install the hair-pin clip
into the caliper assembly.
9. Repeat steps 5-8 for the inner pad;
then secure the pad with the hairpin
clip.
10. Remove the reservoir cover and
remove the remaining fluid; then fill
the reservoir with fresh fluid and
install the cover.
11. Pump the brake lever to ensure cor-
rect positioning of the brake pads and
proper brake lever travel; then release.
NOTE: If brake lever travel is not
within specification, bleed the brake
system.
12. Remove the reservoir cover and fill
the reservoir (if necessary) to the
proper level with fresh brake fluid;
then install the cover.
13. Secure the brake shield, the driven
clutch (tightened to 20 ft-lb); then
close and secure the left-side access
panel.
NOTE: When new brake pads are
installed, a “burnishing” process is
required (see Burnishing Brake Pads
sub-section).
Burnishing Brake Pads
After changing brake pads, the new brake
pads must be burnished to achieve full
braking effectiveness. Braking distance
will be extended until brake pads are
properly burnished.
To properly burnish the brakes, use fol-
lowing procedure:
CAUTION
Brake fluid is highly corrosive. Do not
spill brake fluid on any surface of the
snowmobile.
