Snowmobile Arctic Cat (2004 year). Manual - part 158

9-148

FS061

7. 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 strap 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.

8. Items to replace:

A. Bleed screw O-ring and floating piston O-ring.

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. Set IFP Depth Setting Tool (p/n 0644-350) to 5.90

in.

FS062

2. Lubricate the O-ring and Teflon strap on floating

piston; then press the floating piston into shock
until flush with the top of the body.

FS063

FS064

3. Install IFP tool onto floating piston; then press

floating piston into shock body 5.90 in.

FS065

FS066

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9

4. Install bladder assembly and tighten to 2.1-2.5 kg-

m (15-18 ft-lb).

FS067

5. Fill shock body with lightweight synthetic Shock

Oil (p/n 2639-151) to bottom of threads.

FS068

6. Install by-pass components: 1/4-in. ball, spring

rod, spring, and 5/16-in. ball.

FS069

FS070

FS071

FS072

7. Install the set screw and tighten to 1.0 kg-m (7 ft-

lb).

FS073

8. Install shock rod/piston assembly into body.

9-150

„

NOTE: End cap should be down to piston

assembly (rod fully extended).

FS074

9. While holding up on the eyelet, screw end cap into

the body.

FS076

„

NOTE: Air will bleed out of flat area on end cap.

FS075A

10. Using a 1-in. wrench, tighten end cap.

FS077

11. Pressurize the shock with nitrogen to 200 psi (see

Pressurizing Rebuildable Shocks sub-section).

FS078

12. Install the set screw (with O-ring) into the bladder

housing.

FS079

13. Test operation of the shock.

„

NOTE: Shock should feel soft on compression;

constant on rebound.

9-151

9

FS080

INSTALLING

1. Place the shock into position on the snowmobile.

2. Secure with existing hardware. Tighten to 3.2 kg-

m (23 ft-lb).

Installing Internal 

Travel Limiting Spacers

These spacers are used to shorten the travel of the
shock absorber to fine tune the suspension to the oper-
ator's driving style.

If installing the spacers in the internal floating piston
shock absorbers, follow these steps.

1. Disassemble the shock absorber as covered in this

manual.

2. Place the shock shaft eyelet into a vise and remove

the nut securing the piston to the shock shaft.

AP028

3. Carefully remove the piston and its valving plates

stacked on either side of the piston from the end of
the shock shaft.

„

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

„

NOTE: If the piston assembly should become

mixed, the large slots of the piston must be
located next to the lock nut of the shaft. Refer to
the appropriate Illustrated Parts Manual for valve
plate location.

„

NOTE: If a rubber washer is found on the shock

shaft next to the bottom side of the bearing cap, it
must be removed before installing the limiting
spacers. The rubber washer must not be used with
the spacers installed.

4. Measure the length of the limiting spacer(s) that

are being installed on the shock shaft. Write down
this measurement as it will be required to properly
calculate the floating piston depth later in the
assembly process.

AP053

5. Install the desired number of limiting spacers on

the shock shaft.

AP054