Ski-Doo 2005 MACH Z, Shop Manual, Page: 234 / 343

Section 06 DRIVE SYSTEM
Subsection 05 (BRAKE)
A35D0AA
Torque brake disc nut to 60 N•m (44 lbf•ft) and
further tighten until its grooves align with the next
cotter pin hole.
Install a new cotter pin. Both end of cotter pin
must be folded over nut.
BRAKE LIGHT SWITCH
Removal
The brake light switch no. 17 is located near the
brake lever. To remove the switch, use the follow-
ing.
Disconnect the switch.
Take out the master cylinder from the handlebar.
Overturn the master cylinder so that the bottom is
on the top.
Fix the master cylinder in a rigid way preferably in
a vise.
Pull out the switch wire and rubber cover.
Activate the parking brake.
With the help of a proper tool, unscrew the switch
body pay attention to apply a torque in axial direc-
tion with steps of little torque angles and pay at-
tention to not apply a force in radial direction (flex-
ion).
Remove the glue remaining with alcohol on a
piece of cotton and then clean the seat threads
with the clamp screw. If there is resistance to
the advance of the clamp screw, use a proper
wrench.
NOTE: In case of switch body breaking during the
unscrewing activity, act mechanical restoring the
threads on master cylinder seat and then go on
with the installation procedure.
Installation
NOTE: The brake light switch is not adjustable.
Put the switch on the seat, rotating it only for 1 or
1.5 turns.
Put one drop of Loctite 609 (P/N 413 703 100) on
the free switch threads.
Screw the switch by hand until it is in a correct
position.
For safety reasons, check the activation of the
switch by pulling the brake lever. In case of no
switch activation, repeat all the procedure replac-
ing a new switch.
NOTE: If parking brake release during the mount-
ing operations, set the master cylinder in a sloping
position (with lever on the top) and hold the mas-
ter cylinder lever for 3/4 times.
Reinstall the master cylinder on the handlebar tak-
ing it in a horizontal position avoiding the risk of
glue contamination for the switch rod.
Release the parking brake.
Wait 24 hours to allow glue to set.
Recheck if switch is working properly.
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