Hand Brake Lever/Master Cylinder Assembly - Arctic Cat 08 ATV Service Manual

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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 container. Remove the reservoir cover; then open
the bleeder valve. Allow the brake fluid to drain
completely.
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 from
the master cylinder. Account for two crush wash-
ers and a banjo-fitting bolt.
! CAUTION
Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV.
3. Remove the snap ring and pivot pin securing the
brake lever to the master cylinder housing; then
remove the brake lever and set aside.
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AF637D
DE059A
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4. Dislodge the brakelight switch from the master
cylinder housing by gently pressing it toward the
pivot pin hole in the housing; then lay it aside
leaving the switch and wiring harness connected.
5. Remove the clamp screws securing the brake
housing to the handlebar; then remove the assem-
bly from the handlebar.
INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
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 for cracks and deteriora-
tion and the condition of the fittings (threaded and
compression).
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 Section 5.
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BC205
DE058A
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