Hand Brake Lever/Master Cylinder Assembly - Arctic Cat 2015 400 Service Manual

5. Remove the hub assembly.
6. Remove the four cap screws securing the brake disc.
CLEANING AND INSPECTING
1. Clean all hub components.
2. Inspect all threads for stripping or damage.
3. Inspect the brake disc for cracks or warping.
4. Inspect the hub for pits, cracks, loose studs, or spline
wear.
INSTALLING
1. Secure the brake disc to the hub with the four cap
screws coated with blue Loctite #243. Tighten to 15
ft-lb.
2. Apply grease to the splines in the hub.
3. Install the hub assembly onto the shaft.
4. Secure the hub assembly with the nut. Tighten only
until snug.
5. Secure the brake caliper to the knuckle with two new
"patch-lock" cap screws. Tighten the caliper to 20
ft-lb.
6. Tighten the hub nut (from step 4) to 200 ft-lb; then
install and spread a new cotter pin making sure each
side of the pin is flush to the hub nut.
7. Install the wheel and tighten to 40 ft-lb (steel) or 80
ft-lb (aluminum).
8. Remove the ATV from the support stand.
108
Hand Brake Lever/Master
Cylinder Assembly
 NOTE: The master cylinder is a non-serviceable
component; it must be replaced as an assembly.
REMOVING
1. Slide a piece of flexible tubing over one of the wheel
bleeder valves and direct the other end into a con-
tainer. Remove the reservoir cover; then open the
bleeder valve. Allow the brake fluid to drain com-
pletely.
 NOTE: Compressing the brake lever several times
will quicken the draining process.
2. Place an absorbent towel around the connection to
absorb brake fluid. Remove the banjo-fitting bolt
from the master cylinder. Account for two crush
washers and a banjo-fitting bolt.
KC283
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV.
3. Remove the clamp screws securing the brake hous-
ing to the handlebar, then remove the assembly from
the handlebar.
INSPECTING
1. Inspect the pin securing the brake lever for wear.
2. Inspect the brake lever for elongation of the pivot
hole.
3. Inspect the reservoir for cracks and leakage.
4. Inspect the banjo-fitting and bolt for cracks and dete-
rioration and the condition of the fittings (threaded
and compression).
INSTALLING
KC305
1. Position the brake housing on the handlebar. Secure
with clamp screws; then tighten securely.
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.
CAUTION
AF637D