Arctic Cat 650 Twin2004, Service Manual

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CD006
9. Remove the ATV from the support stand.
Hydraulic
Brake Caliper

NOTE: The brake caliper is a non-serviceable
component; it must be replaced as an assembly.
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 entire hydraulic
system (reservoir, hoses, and caliper).
AF637D
3. Remove the brake hose from the caliper; then
remove the caliper.
AF636D
CLEANING AND INSPECTING
1. Clean all caliper components (except the brake
pads) with parts-cleaning solvent.
2. Inspect the brake pads for damage and excessive
wear.

NOTE: For measuring brake pads, see Section 2.
ASSEMBLING/INSTALLING
1. Push the pistons into the caliper as far as they will
go to allow clearance for the brake pads.
2. Install the brake pads and secure with the pin and
cotter pin.
CD029
3. Place the brake caliper assembly into position and
secure with the cap screws. Tighten the caliper to
2.8 kg-m (20 ft-lb).
4. Place a new crush washer on each side of the brake
hose fitting and install it on the caliper. Tighten to
4.2 kg-m (30 ft-lb).
5. Fill the reservoir; then bleed the brake system (see
Section 2).
6. Install the wheel. Tighten to 5.5 kg-m (40 ft-lb).
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.
! CAUTION
Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV and do not reuse
brake fluid.
! CAUTION
Care should be taken that the piston and cylinder
are not scratched.