Snowmobile Arctic Cat (2004 year). Manual - part 138

9-68

FC180

FC178

7. Using a plastic mallet, tap the axle from the lower

shock eyelet.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect all front arm weldments for cracks or

unusual bends.

2. Closely inspect all tubing for cracks or unusual

bends.

3. Inspect the bearings, bushings, and front arm spac-

ers for wear or damage.

4. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock
shaft enters the shock body.

5. Inspect the shock absorber eyelet welds (at each

end) for any cracks, signs of separation, or for
unthreading.

6. Inspect the shock absorber and reservoir hoses (on

models with remote adjuster) for damage.

INSTALLING

1. Install the axle into the lower shock eyelet bushing

assembly. Apply grease to the axle; then install the
spacers.

FC178

2. Place the shock mount axle into position on the

skid frame making sure the spacers and washers
are properly positioned. Secure with the cap
screw, washer, and a new lock nut. Tighten to
4.7 kg-m  (34 ft-lb).

FC182

3. Position the front arm with spacers into the mount-

ing brackets. Secure with cap screws and lock
nuts. Tighten to 4.2 kg-m (30 ft-lb).

AG565D

4. Secure the upper shock eyelet and serrated axle in

the appropriate mounting hole of the front arm
(standard arm mounting position). Secure with a
cap screw and lock nut. Tighten to 3.2 kg-m
(23 ft-lb).

9-69

9

AG564D

5. Secure the limiter straps with cap screws, washers,

and lock nuts. Tighten to 1.1 kg-m (8 ft-lb).

FC173

6. Secure the front outer idler wheels to the idler

wheel mounting blocks with cap screws, flat
washers, inserts (if applicable), axles, and lock
nuts. Tighten to 3.2 kg-m (23 ft-lb).

FC151

AG512D

Rear Shock Absorber 

and Shock Links

„

NOTE: Before removing the skid frame by using

the Rear Suspension Spring Tool (p/n 0144-311),
remove the spring from the adjusting cam.

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

DISASSEMBLING

„

NOTE: When removing center components from

the skid frame, it is advisable to loosen all cap
screws/lock nuts from one side of the slide rail to
make removing easier.

1. Disengage the shock absorber at the upper eyelet

and remove the shock absorber. Account for a
sleeve, cap screw, lock nut, and bushings.

FC184

! CAUTION

Care must be taken when removing the spring
from the adjusting cam or damage or injury
could result.

9-70

AG665D

2. Disengage the shock absorber at the lower eyelet.

Account for washers, link axles, bushings, shock
sleeve, cap screw, and a lock nut.

FC188

3. Note the hole location that the spring slides are in;

then remove the cap screws and flat washers
securing the spring slides to the rails. Account for
slide blocks.

FC185

4. Tap the shock pivot assembly forward until it

clears the mounting brackets; then lift the assem-
bly upward until the shaft clears the rails.

FC186

„

NOTE: Lay components out in order as they are

removed.

5. With the pivot assembly removed, account for the

two spacers, an axle, and the pivot bracket; then
noting the hole location for assembling purposes,
remove the cap screw, lock nut, and washer secur-
ing the shock rod links to the rear arm of the skid
frame. Account for a spacer and two link axles.

FC187

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean shock pivot and idler wheel axle in part-

cleaning solvent. Dry with compressed air.

2. Clean the idler wheel bearings with a clean cloth.

3. Closely inspect the torque link arm and axles for

wear, bends, or damaged splines at either end.

4. Inspect the idler wheels for signs of cracking,

wear, or outer rubber separation from plastic
wheel.

5. Rotate the idler wheel bearings (by hand) and

inspect for any signs of binding or roughness.

! WARNING

Always wear an approved pair of safety glasses
when using compressed air.

9-71

9

6. If a bearing must be replaced, use this procedure.

A. Remove the snap ring.

B. Using a hydraulic press, press the bearing out

the inside of the wheel.

C. Press the new bearing (on its outer race) into

the idler wheel.

AG538D

D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.

AG539D

7. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock
shaft enters the shock body.

8. Inspect the rubber shock bushings located in the

shock absorber eyelets for cracks or deterioration.

9. Inspect the shock absorber eyelet welds (at each

end) for any cracks or signs of separation.

10. Inspect the welds securing the eyelets of the shock

links for cracks or signs of separation. Either weld
the eyelet or replace the shock link.

11. Inspect the axle surfaces for any signs of corro-

sion. If corrosion is found, lightly buff the surface
of the axle with #400 wet-or-dry sandpaper; then
apply a light coat of grease.

ASSEMBLING

1. Position the shock links in the appropriate holes of

the idler arm brackets (see Chassis and Skid Frame
Mounting Locations in this section). Place a
spacer between the center of the brackets; then
place a flat washer on the cap screw. Insert the link
axles into the upper shock link eyelets. Secure
with a cap screw, washer, and lock nut. Tighten to
4.2 kg-m (30 ft-lb).

AG682D

2. Secure the shock absorber to the idler arm with

bushings, sleeve, lock nut, and a cap screw.
Tighten to 4.2 kg-m (30 ft-lb).

FC184

3. Apply a thin coat of low-temperature grease to the

axle and slide the axle into the shock pivot
bracket. Have equal amounts of the axle exposed
on either side of the bracket tube.

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.