Front Brake Lever/Master Cylinder Assembly - Arctic Cat ATV 300 Utility/DVX 300 2011 Service Manual

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Front Brake Lever/Master
Cylinder Assembly
 NOTE: The master cylinder is a non-serviceable
component; it must be replaced as an assembly.
REMOVING
1. Connect a clear hose to the bleed screw on either
front brake caliper; then open the bleed screw and
pump the brake fluid into a suitable container. Close
the bleed screw.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV.
 NOTE: Do not reuse brake fluid. When exposed to
air, brake fluid rapidly absorbs moisture.
2. Remove the brakeline hose union bolt; then remove
the cap screws securing the master cylinder assembly
to the handlebar. Discard the crush washers from the
union bolt.
3. Remove the brake lever, brakelight switch, and brake
lever lock.
4. Using new crush washers, secure the brake hose to
the master cylinder with the brake hose union bolt.
INSPECTING
 NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
1. Inspect the pivot bolt 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 brake hose for cracks and deterioration
and the condition of the fittings (threaded and com-
pression).
5. Inspect the brakelight switch for corrosion, cracks,
missing or broken mounting tabs, or broken and
frayed wiring.
 NOTE: If the brakelight switch is determined to be
not serviceable, see Electrical System.
INSTALLING
1. Install the brakelight switch on the master cylinder;
then install the brake lever and brake lever lock.
2. Install the master cylinder assembly on the handlebar
engaging the alignment stud in the hole in the han-
dlebar; then secure with the master cylinder clamp
and two cap screws. Make sure the UP arrow on the
clamp is directed upward.
KM116A
3. Tighten the cap screw (1) to 13 ft-lb; then tighten the
cap screw (2) to 13 ft-lb.
KM800A
Tighten to 25 ft-lb.
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KM800B
KM800B
113