Snowmobile Arctic Cat (2004 year). Manual - part 157

9-144

AP032

14. Items to inspect:

A. Shock shaft for straightness, nicks, or burrs.

B. Shaft bearing end cap — clean, inspect, or

replace.

C. Inside of shock body for scratches, burrs, or

excessive wear.

D. Piston rings for cuts, chipped or nicked edges,

or excessive wear.

E. O-rings for nicks, cuts, or cracks.

F. Valves for kinks or waves.

G. Rubber damper (ski shocks only) for chipping,

cracking, or being missing.

15. Items to replace:

A. Bleed screw O-ring on the floating piston.

B. Shock shaft bearing cap if any signs of oil leaks

or damage.

C. Any part worn or damaged.

„

NOTE: For shaft, shaft eyelets, or shaft bearing

cap replacement, see Shaft Eyelet or Bearing Cap
and Shaft Seal sub-section.

ASSEMBLING

1. Place the shock shaft eyelet into the vise; then

assemble valves and piston and tighten the lock
nut to 2.1-2.8 kg-m (15-20 ft-lb).

2. Place the shock body between the two Gas Shock

Retaining Blocks (p/n 0644-142) and secure in a
vise.

3. Apply a light coat of oil on the O-ring and piston

ring and install piston into shock body.

AP033

4. Place the shaft bearing cap into the body and

tighten securely.

AP026

5. Loosen vise and reposition the shock body and

retaining blocks so the bottom of the shock body is
“up” and in a vertical position. Extend the shock
shaft fully and fill the shock body with Shock Oil
(p/n 1639-245) to within 1-1 1/2-in. from the top.

! CAUTION

DO NOT OVER-TIGHTEN. If excessive torque is
applied, damage to the piston and valves will
occur.

! CAUTION

It is important that the Gas Shock Retaining
Blocks (p/n 0644-142) are used during both
disassembly and assembly. Any other method of
securing the shock body during these
procedures may deform the shock body cylinder.

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9

6. Slowly move the shock shaft up and down a few

times keeping the piston under oil at all times.
This is to remove the air from under the piston.
Extend the shock shaft fully; then fill the shock
body with oil to within 1/2-3/4-in. from the top.

„

NOTE: After filling the shock body with oil, allow

5 minutes for all air bubbles to rise to the top.

7. Apply a light coat of oil on the floating piston ring

and O-ring and install the floating piston in the
shock body.

AP023

„

NOTE: Depending on which shock absorber is

being worked on, adjust the piston location tool to
the specification indicated in the Rebuildable
Shock Piston Depth Chart in this section.

AP050

8. Attach the Shock Piston Location Tool (p/n 0644-

169) to the piston by placing its slotted end over
the flats on the top of the piston and giving the tool
a quarter turn. Pull gently on the tool to make sure
it is secure to the piston.

AG339

9. Using the tool as a handle, push the piston down

into the shock body until the adjustment knob
comes in contact with the shock body. Give the
tool a quarter turn to free it from the piston. The
piston should now be located correctly.

729-085C

„

NOTE: As the floating piston is pushed into the

shock absorber body, air and excess oil will come
out through the hole in the piston. If no oil comes
out through the hole in the piston, remove the pis-
ton and add more oil to the shock body.

10. Install the Allen-head screw and O-ring into the

bottom of the floating piston. While securing the
piston with a 9/16-in. wrench, tighten the Allen-
head screw.

AP020

11. Pour out the excess oil from the shock body.

12. Install the lower end cap on the shock body.

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13. Using Shock Retaining Blocks (p/n 0644-142) to

hold the shock in place and using an adjustable
wrench, tighten the end cap securely.

AP016DA

14. Apply a light coat of oil on the bladder housing O-

ring; then install the brass bladder housing into the
lower end cap. Tighten securely.

AP014

15. Pressurize the shock (see Pressurizing Rebuildable

Shocks section). After shock has been pressurized,
install screw into bladder housing. Tighten
securely.

16. Install shock eyelet bushings and axle.

Servicing Position 

Sensitive Shock

REMOVING/CLEANING

1. Remove the shock from the snowmobile.

2. Wash the shock body in parts-cleaning solvent;

then dry with compressed air to remove sand and
dirt.

DISASSEMBLING

1. Remove the screw from the bladder housing on the

bottom of the shock. Discharge all the pressure
from the shock using the Shock Inflation Needle
(p/n 0644-158). Open the valve in filler handle
until all pressure is released.

FS081

FS052

FS053

2. Using a 1-in. wrench, loosen the end cap and

remove the shock rod and valve assembly from the
shock body.

! WARNING

Before any service is performed on the gas shock
absorber, first discharge all pressure from the
shock remote reservoir. Remove the valve screw
from the pressure valve and insert the Shock Infla-
tion Needle (p/n 0644-158). Open valve until all pres-
sure is released. Failure to do this may cause
personal injury.

! WARNING

When using compressed air to dry components,
always wear safety glasses.

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9

FS054

FS055

3. Pour the oil from the shock body into a suitable

container.

FS056

4. Using a 3/16-in. Allen wrench, remove the set

screw.

FS057

FS058

„

NOTE: Account for a set screw, 5/16-in. ball,

spring, spring rod, and a 1/4-in. ball.

FS059

5. Remove the pressure valve assembly. Account for

the O-ring.

FS060

6. Using IFP Removal Tool (p/n 0644-348), remove

the floating piston.