Table Of Contents; Manual - Arctic Cat XC 450i 2012 Service Manual

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
INSPECTING
 NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
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
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.
3. Bleed the brake system (see Periodic Maintenance).
Hydraulic Brake Caliper
! WARNING
Arctic Cat recommends that only authorized Arctic Cat
ATV dealers perform hydraulic brake service. Failure to
properly repair brake systems can result in loss of con-
trol causing severe injury or death.
REMOVING/DISASSEMBLING
1. Secure the ATV on a support stand to elevate the
wheel; then remove the wheel.
! WARNING
Make sure the ATV is solidly supported on the support
stand to avoid injury.
! WARNING
Never let brake fluid contact the eyes. Damage to the
eyes will occur. Always wear appropriate protective
safety goggles and latex gloves when handling brake
fluid.
2. Drain the brake fluid from the caliper, hose, and mas-
ter cylinder through the bleed screw by pumping the
brake lever/pedal.
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Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV and do not reuse brake fluid.
 NOTE: Whenever brake components are removed,
disassembled, or repaired where brake fluid is
exposed to air, drain all fluid and replace with new
DOT 4 brake fluid from an unopened container. Brake
fluid readily absorbs moisture from the air signifi-
cantly lowering the boiling point. This increases the
chance of vapor lock reducing braking power and
increasing stopping distance.
3. Remove the brake hose from the caliper and close
the bleed screw; then remove the caliper.
4. Compress the caliper holder against the caliper
(opposite the O-ring side) and remove the outer
brake pad; then remove the inner brake pad.
 NOTE: If brake pads are to be returned to service,
do not allow brake fluid to contaminate them.

Manual

Table of Contents

CAUTION
PR235
PR237A
PR238