31
Checking/Changing Brake
Pads
The condition of the brake pads must be
checked daily and changed if worn or
damaged. To check and change the brake
pads, use the following procedure:
NOTE: The brake pads may be
changed by the snowmobile owner if
qualified to do so. If the owner does
not feel qualified, take the snowmo-
bile to an authorized Arctic Cat
Snowmobile dealer for this service.
This service is at the discretion and
expense of the snowmobile owner.
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.
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
securing 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. Pull the brake pads out of the caliper
assembly.
ZR-390
6. Measure the thickness of the brake pad.
The brake pad thickness must be greater
than 1.0 mm (0.04 in.). If the brake pad
thickness is less than specified, replace-
ment of both pads is necessary.
PC011A
7. Position the outer brake pad into the
caliper; then install the hairpin clip
into the caliper assembly.
8. Repeat for the inner pad; then secure
the pad with the hairpin clip.
9. Remove the reservoir cover and
remove the remaining fluid; then fill
the reservoir with fresh fluid and
install the cover.
10. 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.
11. Remove the reservoir cover and fill
the reservoir (if necessary) to the
proper level with fresh brake fluid;
then install the cover.
12. Secure the brake shield; 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).
CAUTION
Brake fluid is highly corrosive. Do not
spill brake fluid on any surface of the
snowmobile.
