how to change your brakes

Brake Disassembly

Step 1:
Have the replacement parts in hand before you start this project.

We have found the stock replacement brake pads to be made with a softer compound, while aftermarket pads tend to be a harder compound. Soft pads definitely brake better, but they tend to wear out faster. While the hard pads take more effort to pull on the brakes, they last a long time and tend to wear into the brake rotor when compared to the stock pads. So choose your pads accordingly.

Step 2:
Bend the metal security tab away from the caliper mounting bolts. This is a simple task that can be done with a standard screwdriver and a tap with a hammer.

Step 3:
Remove the mounting bolts. Then the caliper can be lifted away from the brake rotor. Be careful when handling the caliper and the flexible brake line and do not put any stress on the flex line.

Step 4:
Remove the spring retainers, with a standard screwdriver and pull the retaining pins out. If theses pins are stuck, one can pull them out with a pair of pliers. With the pins removed, the pads can be removed.
NOTE: Sometimes the pads are completely worn away and the metal backing wears against the brake rotor. This is what gives you that brake squeal.

Brake Assembly

Step 1:
With everything apart, it's time to reassemble. The new pads are thicker when compared to the old pads, so the distance in the caliper needs to widen to accommodate the thicker pads. This is done with C-clamps or in this case a pair of Vise-Grip tongs. One needs to push the caliper piston back into the caliper. In this case Ski-Doo uses a dual piston setup, two pistons, one from each side, both pistons need to be pushed back in order to make more room for the thickness of the new pads.
NOTE: If the pads do not retract easily, then loosen the brake fluid bleed screw, and drain some fluid. Be careful with brake fluid, it can be toxic and can remove paint. An instant cleanup is in order. Use a plastic hose that will help to bleed and control the fluid. Now is also a good time to clean the brake rotor with brake clean solvent, spray and wipe dry and try to clean the entire rotor and surrounding parts.

Step 2:
With the pistons backed off, drop the new pads in. Also, check the retaining shafts for wear before replacing the retaining pins. This shaft should be smooth, and one can sand any wear marks smooth. If the shaft is bad you should get new pins.

Step 3:
Replace the retaining pins. A trick here is to align the pins upside down. This will give the pads a new surface to slide on. These pins have a hole in them to accommodate the spring retainers. Put a light coat of grease on these pins before sliding them into position. This helps create a smoother mechanical brake operation. Replace the spring retainers and drop the caliper assembly into position, making sure that the pads are on both sides of the brake rotor. You can use a standard screwdriver to manipulate this assembly into position.

Step 4:
Once the caliper is in position, you can replace the caliper mounting bolts; don't forget the metal security tab retainer. Using a set of channel locks, it's easy to fold the retainer tab back into a safe, locked position.

Step 5:
If you didn't need to break the seal in the brake line fluid, just pump the sled's brake lever until the pressure returns. If you did break the seal, you will need to bleed the brake system. Always use the proper DOT brake fluid that is recommended for your machine and always use a new bottle, old brake fluid absorbs moisture and becomes contaminated quickly.
In order to top off the master cylinder with brake fluid (resevoir on the handlebars) use a plastic line on the bleed screw and put the other end into a brake fluid container, pump the brake lever until there is pressure. With one hand holding the pressure on the lever, use your other hand to open the bleed screw, to drain the pressure/air/fluid. Be quick to shut off the screw before the pressure is all gone. Try to maintain a little pressure when draining. Repeat this procedure until the fluid is clear with no air bubbles and it has a solid feel. Tighten the bleed screw and remove any brake fluid.
Congratulations, you're done!