Brake Lever/Master Cylinder Assembly - Arctic Cat 2015 ZR 5000 Service Manual

8. Install new brake pads in the caliper and secure with
the retainer pin.
9. Bleed the brake system.
10. Install the brake shield and footrest; then install the
drive belt and driven clutch. Tighten the driven
clutch cap screw to 20 ft-lb.
11. Adjust the track tension and track alignment.
12. Close and secure both side panels.
Brake Lever/Master
Cylinder Assembly
REMOVING
1. Slide a piece of flexible tubing over the ball of the
bleeder valve and direct the other end into a con-
tainer.
2. Remove the two screws securing the reservoir cover
and remove the reservoir cover; then open the
bleeder valve. Allow the brake fluid to drain com-
pletely.
3. Place an absorbent towel around the connection to
absorb brake fluid. Remove the banjo-fitting bolt (A)
securing the brake fluid hose (B) to the master cylin-
der. Discard the two crush washers.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the snowmobile.
168
4. Remove the pin (D) securing the brake lever to the
master cylinder.
PC195
5. Using a small screwdriver, compress the tabs of the
brakelight switch (E) to release it from the master
cylinder.
6. Remove the two torx-head screws (F) and clamp
securing the brake reservoir to the handlebar; then
place a towel over the reservoir and remove the
assembly from the handlebar.
INSPECTING
1. Inspect the snap ring and pin securing the brake lever
for wear or damage; then inspect the brake lever for
cracks or damage.
2. Inspect the master cylinder reservoir and cover for
cracks and leakage.
 NOTE: The master cylinder is a non-serviceable
component. If any wear or damage is detected, the
master cylinder must be replaced.
3. Inspect the brake fluid hose for cracks, deterioration,
and the condition of the fittings (threaded and com-
pression).
INSTALLING
1. Position the brake assembly on the handlebar. Secure
with two torx-head screws (F) and clamp; tighten
securely.
2. Install the brake fluid hose (B) to the master cylinder
with the banjo-fitting bolt (A) and two new crush
washers. Tighten securely.
PC223A
Always use new crush washers when installing the
brake fluid hose.
3. Install the brakelight switch (E) to the master cylin-
der.
4. Install the brake lever; then secure with pin (D).
5. Place the reservoir cover onto the reservoir; then
secure with the two screws.
6. Bleed the brake system.
CAUTION
745-759A