ATV Installation Instructions -Service Parts Kit

 ATV Installation Instructions -Service Parts Kit 

                                           ---Auxiliary Brake Master Cylinder Kit            

https://www.brake-cylinder.com/search/ARCTIC%20CAT.html          

■ NOTE:Read these installation instructions thoroughly before beginning the installation process.Retain these Installation Instructions for future reference.

Application fit for Arctic Cat ATV:- 2004/2005400/500 FIS and 650 Twin FIS

                                                       - 2005650 H1 and 400/500 TBX

■ NOTE:Retain all hardware unless stated other- wise.

1.Place the ATV onto an elevated stand; then remove the rear right-side tire.

2.Remove the cotter pin securing the master cylinder rod clevis to the auxiliary foot brake lever. Account for a flat washer(located

on the outer side of the clevis pin).Remove the clevis pin Dis- card the cotter pin

3.Remove the machine screw and nut securing the remote reservoir to its mounting position.

4.Remove the brake-line hose from the master cylinder.Remove the outer crush washer from the banjo bolt;then remove the

banjo bolt and second crush washer.Discard crush washers.

5.Remove the two cap screws securing the master cylinder to the frame and discard;then remove the master cylinder assembly.

■ NOTE:If you have previously installed the Heavy Duty Auxiliary Brake Kit(p/n 0436-746 or 0436- 747),remove the bracket installed from either of these kits and discard.

6.Place the Master Cylinder Bracket (A)onto existing master cylinder frame bracket (B);then insert and hand tighten the two new 8mmx1.25 Cap Screws (C)to hold the bracket in place for proper centering of hole to be drilled in frame brace. Using a marker or a snap punch,mark the lower left mounting location(D)on the left-side leg of the bracket.Remove the bracket.See Fig.1.

7.Using an 8.73 mm(11/32 in)drill bit,drill a hole through the brace in the marked location. 

8.Position the master cylinder bracket onto the exis- frame bracket,then insert the two 8mm x 1.25 in cap screws into the frame bracket.From the rear side of the frame bracket,install the remaining 8 mm x 1.25 cap screw.Tighten the three cap screws to 3.5 kg-m(25ft-Ib).See Fig.1.

9.Install the new Master Cylinder Assembly onto the new bracket using the two new 6 mm x 1.0x25 Cap Screws.Tighten to 3.5 kg-m (25 ft-b).

10.From outside brake-line hose fitting,insert the existing banjo bolt w/new Crush Washer through the brake-line hose fitting:then install the remaining crush washer onto the banjo bolt.

11.Properly position the brake-line hose fitting onto the top of the master cylinder by turning the fitting toward the frame;then loosely thread the banjo bolt into the top of the master cylinder.

12.Position the brake-line hose so there is at least 6.35 mm(1/4 in)of clearance between the brake-line hose and the frame tube;then tighten the banjo bolt to 2.8 kg-m (20 ft-1b).

13.Position the remote reservoir in its original mounting location and secure with the original machine screw and nut.Secure the brake-line hose with provided Cable Ties as needed.

■NOTE:For 2004 models,continue with steps 14-21 before completing steps 22-27.For other models,skip steps 14-21 and continue with steps 22-27.

14.Position the Reservoir Mounting Bracket onto the lower right rear comer of the battery box.See Fig. 2 for proper location of mounting bracket.

■NOTE:The bottom of the bracket should be flush with the bottom of the battery box,and the rear contoured edge of the bracket should be aligned vertically with the rear of the battery box.If the bracket is positioned incorrectly (too far to the rear of the battery box),the remote reservoir may come into contact with the storage compartment. See Fig.3.

15.With the bracket properly positioned,mark the center of the bracket-to-battery box mounting hole;then set the bracket to the side.

16.Remove the battery hold-down bracket and move the battery as far to the left as possible.

17.Using a 6 mm drill bit,carefully drill the bracket mounting hole.

18.From inside the battery box,insert a 6 mm x 1.0 Machine Screw through the bracket mounting hole;then secure the bracket

to the battery box with a 6 mm Flange Nut.

19.Secure the remote reservoir to the reservoir mounting bracket using a 6 mm x 1.0 x 16 Machine Screw and a 6 mm Flange

Nut.

20.Properly position the battery and secure with the hold-down bracket.

21.Secure the remote reservoir hose to the frame using a supplied cable tie.

22.Remove the clevis and jam nuts from the new master cylinder push rod.

23.Thread the new Master Cylinder Extension Shaft into the master cylinder push rod until it bottoms out.

24.Install the clevis and jam nuts by first installing the jam nut followed by the clevis and the remaining jam nut onto the

master cylinder extension shaft. Center the clevis on the threaded area of the shaft and finger-tighten the jam nuts.

25.Make sure that the master cylinder rod and the auxiliary brake pedal are fully extended;then secure the master cylinder rod

clevis to the auxiliary brake lever using the existing clevis pin, washer,and new Cotter Pin.Spread the cotter pin.

■ NOTE:If the rod clevis mounting hole does not align with the brake lever mounting hole,it may be necessary to adjust the clevis.The lower clevis jam nut must always have no less than one complete thread exposed below the nut.Be sure to tighten the jam nuts.If additional adjustment is needed, unthread the master cylinder extension shaft from the master cylinder push rod.

26.Install the rear tire and remove the ATV from the elevated stand.Tighten to 5.5-6.2kg-m(40-45ft-1b.).

27.Bleed the auxiliary brake system;then test the brakes to make sure they function properly.Refer to an appropriate ATV Service Manual for proper bleeding procedures.