Snowmobile Arctic Cat (2004 year). Manual - part 159

9-152

6. Install the heavy spacer washer and then the piston

with valve plates located on either side onto the
shock shaft. Check to make sure the piston has
been installed with its large slots positioned next
to the lock nut which secures the assembly to the
shaft.

7. Install the lock nut and tighten to 2.1-2.8 kg-m

(15-20 ft-lb).

AP055

„

NOTE: For installing spacers on an IFP shock,

proceed to step 8. For installing spacers on a
remote reservoir shock, proceed to the appropri-
ate assembly procedure for the type of shock
being serviced.

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

ring. Install piston and the shock shaft assembly
into the shock body.

AP033

9. Place the shaft bearing cap into the shock body

and tighten securely.

AP026

10. Remove the shock body from the vise and re- posi-

tion the shock body and holding blocks in the vise
so its open end is “up.” Extend the shock shaft
fully out; then fill the shock body with Shock Oil
(p/n 1639-245) to within 1-in. from the top.
Slowly stroke the shaft up and down to remove air
from under the piston. Oil may need to be added to
keep the shock full. Fill shock to within 1/4-in.
from the top. Allow 5 minutes for all air bubbles to
rise to the top.

„

NOTE: Before installing the internal floating pis-

ton, refer to the illustration below and calculate the
new piston depth using the measurement taken
earlier of the spacer(s) installed and the formula
provided in the illustration.

0730-266

11. After calculating the new piston depth, measure

out this distance on the shock piston location tool;
then adjust and secure the location knob.

AP050

! CAUTION

Do not over-tighten the lock nut. If excess torque
is applied, damage to the piston and valves will
occur.

When using shock internal travel limiting
spacers on rebuildable shocks with IFP’s
(Internal Floating Piston), the IFP depth
setting must be reduced to compensate for
the spacer height. Use the following formula to
adjust your shock depth setting.

Example:
Spacer height = .500 in.
Old IFP depth = .750 in.
IFP Depth Adjustment = .1165 x .500 = .058 in.
New IFP depth = .750 - .058 = .692 in.

9-153

9

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

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

AG850

13. Using a long needle-nose pliers, insert the floating

piston into the adjuster body until the piston is
flush with the top of the body; then using the pis-
ton location tool as a handle, push the piston down
into the adjuster body until the adjustment stop of
the tool comes in contact with the adjuster body.
The piston should now be located correctly.

AG339

„

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.

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

bottom of the floating piston. Tighten the Allen-
head screw.

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

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

17. Using Retaining Blocks (p/n 0644-142), hold the

shock body in place and tighten the end cap using
an adjustable wrench. Pressurize the shock follow-
ing the shock pressurizing procedure.

Servicing Rebuildable 

Shocks & Remote 

Reservoir

REMOVING AND DISASSEMBLING

1. Remove the shock absorber from the snowmobile.

Remove the mounting bushings and bearings from
the shock.

2. Wash the shock body and reservoir in parts-clean-

ing solvent; then dry with compressed air to
remove sand and dirt.

3. Remove the screw from the bladder housing on

bottom of shock reservoir; then discharge all pres-
sure from the shock reservoir using Shock Infla-
tion Needle (p/n 0644-158). Open valve in filler
handle until all pressure is released.

AG851

! WARNING

Before servicing a gas shock absorber, first dis-
charge all pressure from the reservoir. Remove the
screw from the top of the reservoir and insert the
Shock Inflation Needle (p/n 0644-158). Open valve
until all pressure is released. Failure to do this may
cause personal injury.

! WARNING

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

! WARNING

When working with Shock Inflation Needle (p/n
0644-158), use extreme care. Misuse of this tool
may cause personal injury or death. Avoid punctur-
ing skin with needle. Pressurized air injected
through the skin may be fatal. Do not release safety
mechanism unless red nose piece is inserted in
shock absorber air valve.

! WARNING

Failure to remove pressure from shock reservoir
may result in personal injury.

9-154

4. Clamp the shock body eyelet in a vise; then using

a 1-in. wrench, unscrew the shaft bearing cover.

„

NOTE: If the shock body turns in lower end cap,

use shock blocks to hold the shock.

AG852

5. With the bearing cover loosened, lift the shaft

assembly from the shock body.

AG853

6. Remove the piston ring from the piston.

7. Loosen (BUT DO NOT REMOVE) the self-lock-

ing nut from the bottom of the shock shaft; then
clean the piston area with clean parts cleaner to
remove any dirt or foreign material from between
the valves. Dry the piston and valves completely
using compressed air. Tighten self-locking nut to
2.1-2.8 kg-m (15-20 ft-lb). Do not over-tighten! If
excess torque is applied, the piston and valves will
be damaged.

AG280

„

NOTE: Do not remove the self-locking nut from

the bottom of the shock rod unless piston or pis-
ton valve changes are needed as it is very impor-
tant the valving on either side of the piston stay in
the proper position.

8. Install the piston ring on the piston.

9. Push down on the reservoir end cap compressing it

2.5 cm (1 in.) into the reservoir; then remove the
reservoir cap retainer ring. Use care not to scratch
the inside of the reservoir.

AG854

„

NOTE: With the retainer ring removed, wipe the

ring area clean to remove any foreign materials.

10. Remove the reservoir end cap by grasping the

bladder housing with a pliers and pulling the cap
slowly out of the reservoir body.

AG855

11. Remove the Allen-head screw and O-ring from the

center of the piston. Remove the piston from the
reservoir by grasping the raised area of the piston
using a pliers. Pull the piston from the reservoir
and account for the piston ring.

9-155

9

AG856

12. Pour the oil out of the shock and reservoir; then

clean the inside of the reservoir and shock body
using clean parts washer solvent. Blow dry using
compressed air.

„

NOTE: If the shock bearing cap does not show

signs of leakage or damage, do not remove from
the shaft.

13. Inspect shock shaft for straightness, nicks, or

burrs. Inspect shock and reservoir bodies for dents
or scratches. Inspect piston valves for bending or
cracking. Inspect all O-rings and seals for nicks,
cuts, or cracking. Inspect rubber bottom-out
bumpers for wear or damage. Replace any worn or
damaged parts.

„

NOTE: If changing or removing shock shaft seal,

bearing cap, eyelet, or bottom-out bumper, refer to
those sub-sections.

ASSEMBLING

1. Place the shock into a vise at a slight angle and fill

the shock reservoir with Shock Oil (p/n 1639-
245).

AG857

„

NOTE: If filling shock with a remote reservoir,

hold the reservoir lower than the shock. By hold-
ing the reservoir low as oil is added to the reser-
voir, air in the hose will be forced into the shock
body and out of the system.

2. With the Allen-head screw and O-ring installed in

the reservoir piston and the reservoir full of shock
oil, compress the piston ring into position with fin-
gers and slowly push the piston down into the res-
ervoir until the O-ring is down in the reservoir
housing.

AG858

3. Let the reservoir hang down for a few minutes to

let air bubbles rise to the top and into shock body.

4. Using a clean pair of pliers, grasp the hex area at

the center of the piston and slowly push the piston
down into the reservoir until it bottoms in the res-
ervoir. Once the piston has bottomed out in the
reservoir, slowly pull up on the piston approxi-
mately ½ in. Next, slowly push the piston back
down until it once again bottoms. Repeat this pro-
cedure several times until no air bubbles are seen
rising in the oil in the shock body.

„

NOTE: The oil in the reservoir will remove any air

in the hose or passageway between the reservoir
and shock body.

5. Once all air has been removed from the reservoir

body, bottom the piston in the reservoir and then
pull the piston upward approximately 1/8 in.
Allow the reservoir to hang down below the shock
absorber in the vise to permit any air that might
remain in the reservoir to rise into the shock body.

AG859

! WARNING

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