Arctic Cat® ATV - Country Cat Country Cat

Form No. 0453-475
Arctic Cat® ATV
Installation Instructions - Service Parts Kit
Auxiliary Brake Master Cylinder Kit
(p/n 0437-053)
„ NOTE: Read these installation instructions thoroughly before beginning the installation process. Retain
these Installation Instructions for future reference.
Application:
2004/2005 400/500 FIS and 650 Twin FIS
2005 650 H1 and 400/500 TBX
Kit includes:
p/n
QTY
DESCRIPTION
0502-881
8408-625
8408-816
1502-263
1502-256
0402-584
0423-178
0123-788
1506-521
8476-616
8424-602
0453-475
Master Cylinder Assembly
Cap Screw (6 mm x 1.0 x 25)
Cap Screw (8 mm x 1.25 x 16)
Master Cylinder Extension Shaft
Master Cylinder Bracket
Cotter Pin
Crush Washer
Cable Tie
Reservoir Mounting Bracket
Machine Screw (6 mm x 1.0 x 16)
Flange Nut (6 mm x 1.0)
Instructions
1
2
3
1
1
1
2
2
1
1
1
1
6. Place the Master Cylinder Bracket (A) onto existing master cylinder frame bracket (B); then insert
and hand tighten the two new 8 mm x 1.25 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.
Fig. 1
„ NOTE: Retain all hardware unless stated otherwise.
1. Place the ATV onto an elevated stand; then
remove the rear right-side tire.
742-445A
7. Using an 8.73 mm (11/32 in.) drill bit, drill a hole
through the brace in the marked location.
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. Discard the cotter pin.
8. Position the master cylinder bracket onto the exisframe bracket; then insert the two 8 mm 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 (25 ft-lb). See Fig. 1.
3. Remove the machine screw and nut securing the
remote reservoir to its mounting position.
4. Remove the brakeline 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.
9. Install the new Master Cylinder Assembly onto the
new bracket using the two new 6 mm x 1.0 x 25
Cap Screws. Tighten to 3.5 kg-m (25 ft-lb).
10. From outside brakeline hose fitting, insert the
existing banjo bolt w/new Crush Washer through
the brakeline hose fitting; then install the remaining crush washer onto the banjo bolt.
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 0436747), remove the bracket installed from either of
these kits and discard.
11. Properly position the brakeline 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 brakeline hose so there is at least 6.35
mm (1/4 in.) of clearance between the brakeline
hose and the frame tube; then tighten the banjo
bolt to 2.8 kg-m (20 ft-lb).
1
13. Position the remote reservoir in its original mounting location and secure with the original machine
screw and nut. Secure the brakeline hose with provided Cable Ties as needed.
17. Using a 6 mm drill bit, carefully drill the bracket
mounting hole.
„ NOTE: For 2004 models, continue with steps 1421 before completing steps 22-27. For other models, skip steps 14-21 and continue with steps 2227.
Use extreme care when drilling to avoid drilling into
the battery or battery cable.
14. Position the Reservoir Mounting Bracket onto the
lower right rear corner of the battery box. See Fig.
2 for proper location of mounting bracket.
Fig. 2
! CAUTION
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.
ATV-015A
„ 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.
Fig. 3
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 th
threaded area of the shaft
and finger-tighten the jam nuts.
25. Make sure that the master cylinder rod and the
auxiliary brake pedal ar
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.
ATV-016A
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.
Printed in the U.S.A.
26. Install the rear tire and remove the ATV from the
elevated stand. Tighten to 5.5-6.2 kg-m (40-45 ftlb.).
27. Bleed the auxiliary brake system; then test the
brakes to make sure they function properly. Refer
to an appropriate Arctic Cat ATV Service Manual
for proper bleeding procedures.
®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
2
0307