Snowmobile Arctic Cat (2002 year). Manual - part 177

9-186

Bearing Cap

and Shaft Seal

REMOVING AND DISASSEMBLING

1. With shaft assembly removed from shock body,

clamp shaft eyelet in vise and remove the lock nut.

AP028

2. Lift the piston valve assembly.

„

NOTE: When removing the piston and valve

plates from the shock shaft, place the piston
assembly on a 5/16 x 3-in. cap screw and secure
with a nut to keep the assembly in its proper order.

AP032

3. Remove the bearing cap (on front arm adjuster

shocks, remove the adjuster piston and a spacer

washer first).

4. Remove the outer plastic wiper; then remove the

inner rubber wiper from the bearing cap.

AG257

5. Using a small paper clip bent on one end, remove

the inner O-ring.

AG258

ASSEMBLING AND INSTALLING

1. Install new O-ring and inner rubber wiper into the

shaft bearing cap; then install outer plastic wiper.

AG259

2. Inspect the shoulder or step of the shaft for sharp

edges or a burr. Smooth up with #400 grit sand

paper or emery cloth.

3. Put Bearing Cap Installation Tool (p/n 0644-268)

over the threaded end of the shaft.

9-187

9

AP114DA

4. Put a small amount of light grease on the seal and

slide the bearing cap over the tool and onto the

shaft.

AP115DA

5. On a front arm adjuster shock, install the spacer

washer on shaft and install adjuster piston in the

same manner as bearing cap; then remove the

installation tool.

6. Install piston valve assembly. Tighten the self-

locking nut to 2.1-2.8 kg-m (15-20 ft-lb).

AG280

Shaft Eyelet

REMOVING

1. Using Shock Rod Clamping Tool (p/n 0644-277)

to prevent damage to the shaft surface, place the

shock shaft into a vise.

2. Heat the shaft eyelet with a torch to soften the

Loctite.

AG260

„

NOTE: The eyelet must be heated up to 300° for

the Loctite to soften.

3. Using a wrench, unscrew the eyelet from the shaft.

AG261

INSTALLING

1. Clean shaft threads and eyelet threads. 

2. Apply red Loctite to both threads, install the eye-

let, and tighten securely.

9-188

Ski Shocks 

Bottom-Out Bumper

Bottom-out bumper can be replaced by removing

shock eyelet or by removing piston valving assembly

and bearing cap.

Pressurizing 

Rebuildable Shocks

To pressurize the gas shock absorber, a regulator sys-

tem and a nitrogen tank will be needed.

AG271

„

NOTE: Before inserting the needle into the blad-

der, lubricate the needle with light oil to make
installation easier.

1. Insert the Shock Inflation Needle (p/n 0644-158)

into the shock bladder; then open the valve on the

filler handle.

AG335

2. Turn the nitrogen tank valve open and slowly

rotate the regulator T-handle inward until the

gauge reads 200 lb of pressure; then close filler

valve and remove inflation needle.

„

NOTE: On remote reservoir shocks, use a needle

nose vise grips to hold the bladder housing to
keep the end cap from pushing into the reservoir
when inserting the inflation needle.

AG851

3. Install the screw into the bladder housing and

tighten securely.

4. With the reservoir pressurized, push down on the

shock shaft until it nearly bottoms and release it.

The shaft should return to its extended position

smoothly.

„

NOTE: If a soft spot or a mushy area is felt as the

shaft is pushed down, this would indicate air in the
shock body. If there is air in the shock body, dis-
charge the reservoir gas pressure. Disassemble
the shock to the point that the “filling with oil” and
the “bleeding air” procedures can be redone.
Assemble and repeat the pressurizing procedure.
To test the shock absorber for nitrogen gas leaks,
submerge in water.

! WARNING

Never have a nitrogen bottle in the area without
having it chained or secured. If the bottle should tip
over and the regulator break off, the gas inside it is
under 1800 lb of pressure and personal injury may
result.

! WARNING

Always rotate the regulator T-handle to its loose
position each time when finished using the system.
Each time before the nitrogen tank valve is opened,
check to make sure the regulator T-handle is turned
out. When opening the nitrogen tank valve, never
stand in front of the regulator in case there should
be a problem.

9-189

9

Troubleshooting

Track

Problem: Track Edge Frayed — Drive Lugs Worn

Condition

Remedy

1. Track alignment adjusted incorrectly

1. Align — replace track

Problem: Track Worn Adjacent to Outer Drive Lugs

Condition

Remedy

1. Track tension adjusted incorrectly

2. Rear idler wheels dirty — damaged

1. Adjust track tension

2. Clean — replace idler wheels

Problem: Track Ratchets — Slaps Tunnel

Condition

Remedy

1. Track tension adjusted incorrectly (too loose)

2. Drive sprockets misaligned — damaged

1. Adjust track tension (tighten)

2. Align — replace sprockets

Problem: Wear-Strip Wear Excessive

Condition

Remedy

1. Slide rail bent — broken — damaged

2. Track alignment adjusted incorrectly

1. Repair — replace slide rail

2. Adjust track alignment