Master Cylinder - Arctic Cat Cougar Service Manual

396
3. Clean the brake caliper assembly with a brake
parts cleaner and dry with compressed air.
4. Inspect all parts for scratches, gouges, cracks,
pitting or corrosion. Replace any damaged parts.
5. On models with a single piston and one mov-
able pad, inspect the brake studs and bushings
for damage or wear. Install new parts, as neces-
sary.
6. Apply brake fluid to the 0-ring seal and in-
stall in the groove in the caliper bore. Make sure
the sealing ring is not twisted or cut while install-
ing.
7. Coat the piston with brake fluid.
8. Use a twisting motion to insert the piston in
the bore with the open side out.
9 A. On models with a single piston and one
movable pad, proceed as follows:
a. Install the brake studs in the caliper.
b. Assemble the caliper halves and install, but
do not tighten, the two Allen head bolts.
c. Attach the caliper to the dropcase. Tighten
the two studs and two Allen head mounting
bolts to the torque listed in Table 2.
9B. On models with dual pistons, proceed as
follows:
a. Repeat Steps 6-8 to assemble the second
piston.
b. Position the small 0-ring (A, Figure 52) as
shown, then assemble the two halves of the
caliper.
c. Hold the caliper halves together and install
the Allen head bolts (Figure 51). Tighten
the Allen head bolts only enough to hold the
caliper halves together.
d. Attach the caliper to the dropcase and
tighten the mounting bolts to the torque
listed in Table 2.
e. Tighten the two Allen head bolts (Figure
51) to the torque listed in Table 2.
10. Attach the brake line to the caliper. Tighten
the fitting securely.
11. Install the brake pads and secure with the
retaining pin as described in this chapter.
CHAPTER FOURTEEN
12. Fill the system with approved brake fluid
and bleed the system as described in this chapter.
Master Cylinder
Repair parts for the master cylinder are not
available. Service to the master cylinder is lim-
ited to removal of the old part and installation of
a new part. The brake light switch, hand lever and
clamp parts are available.
1. Drain the master cylinder as follows:
a. Attach a hose to the brake caliper bleeder
valve (A, Figure 48, typical).
b. Place the open end of the hose in a clean
container.
c. Open the bleed valve and operate the brake
lever to drain all fluid from the master cyl-
inder reservoir.
d. Close the bleeder valve and remove the
drain hose.