Arctic Cat Cougar Service Manual page 400

390
On 1994 and earlier models, the stationary pad
is bonded to the caliper, but can be removed by
inserting a punch through the hole (Figure 42)
in the caliper. Install the stationary pad of these
early models using Loctite Superbonder Adhe-
sive or equivalent.
Assembly/Installation (1994 and Earlier
Models)
1. Assemble the actuator in the caliper as fol-
lows:
a. Install the locknut and locking tab onto the
adjusting screw (Figure 34).
b. Insert the spiral into the caliper and tum it
until it bottoms.
c. Install the brake actuator
arin
onto the spiral
so it is positioned vertically (Figure 43).
d. Install the locknut and lockwasher on the
adjusting screw and install the screw in the
spiral. Tum the screw until the threaded end
is flush with the end of the spiral.
e. Place the tab of the locking tab (Figure 44)
in the notch of the actuator
arm
and tighten
the locknut finger-tight.
2. Install the pad spring in the caliper, then
install the plate and movable brake pad.
3. Assemble the brake/caliper halves and
bracket (Figure 33). Observe the following.
a. The spacers installed at the top of the
bracket are different. Install the thicker
spacer on the side that faces the engine,
when installed in the snowmobile.
b. The caliper mounting bolts are different.
The bolt head of the front bolt may have
been machined to provide additional clear-
ance for the brake actuator lever.
c. Install the caliper mounting bolts so the
heads are toward the engine.
d. Tighten the caliper bolts to the torque listed
in Table 2.
4. Connect the brake actuating cable as follows:
a. Place the clevis (9, Figure 33) over the end
of the brake cable. Align the hole in the
CHAPTER FOURTEEN
clevis with the hole in the brake actuator
arm and install the clevis pin
(8,
Figure 33).
b. Secure the clevis pin (8, Figure 33) with a
new cotter pin.