Arctic Cat Cougar Service Manual page 402

392
c. Install the spring and washer (Figure 41)
over the temporarily installed mounting
screw.
d. Install the jam nut, tightening the nut until
slight spring pressure is felt. The spring
pressure should be sufficient to hold the
alignment bushing when the screw is re-
moved.
e. Remove the temporarily installed mounting
screw.
2. Assemble the adjuster in the actuator as fol-
lows:
a. Apply a small amount ofMolylube Silicone
Anti-Seize to the threads of the adjusting
screw (Figure 40).
b. Insert the adjusting screw and spring into
the quick-adjust knob. Install the assembly
in the actuating arm. Tum the adjusting
screw a couple of turns.
3. Apply Molylube Silicone Anti-Seize to the
threads of the actuator shaft.
4. Start the actuator arm in the 11 o'clock posi-
tion (Figure 45) and screw the arm into the
caliper.
5. Install the brake cable bracket.
6. Attach the return spring to the bracket and the
actuating arm.
7. Install the brake piston. The notch must en-
gage the roll pin in the caliper.
8. Install the thicker (movable) brake pad, mak-
ing sure the notch engages the roll pin.
WARNING
Make sure the snap ring installed in Step
9 is properly seated before continuing.
Failure to seat the snap ring can result
in injury.
9. Install the snap ring (Figure 37) with the
sharp edge facing out. The opening in the snap
ring should be down as shown.
10. Install the pad support plate with the longer
tab (Figure 38) located in the opening of the snap
nng.
CHAPTER FOURTEEN
11. Install the thinner brake pad with the notch
engaging the smaller tab of the support plate
(Figure 38).
12. Install a rubber band to hold the stationary
pad in place until the caliper is installed.
13. Position the caliper and bracket assembly
over the brake disc and against the dropcase.
14. Apply a small amount of Loctite 271 to the
rear mounting bolt and start the bolt, but do not
tighten it yet.
15. Apply a small amount ofLoctite 271 to the
front mounting bolt and start the bolt. The front
bolt passes through the alignment ball (Figure
41).
16. Tighten both mounting bolts evenly and to
the torque listed in Table 2.
17. Connect the brake actuating cable as fol-
lows.
a. Place the clevis over the end of the brake
cable, then align the hole in the clevis with
the hole in the brake actuator arm. Install
the attaching pin.
b. Secure the clevis pin with a new cotter pin.
c. Check the clevis for freedom of movement.
If the clevis binds, open it slightly with a
screwdriver.
WARNING
If the clevis binds, brake operation may
be erratic. Be sure the clevis moves
freely.
18. Slide the brake cable into the rear slot (Fig-
ure 46) of the cable bracket.