Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 158

9-145

9

Servicing ACT 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 pressure valve assem-

bly on the bottom of the shock. Discharge all the

pressure from the shock using the Inflation Needle

(p/n 0744-020). Open the valve in filler handle

until all pressure is released.

FS250

FS251

2. Using a 1-in. wrench, loosen the bearing assembly

and remove the shock rod and valve assembly

from the shock body.

FS252

FS055

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

container.

4. Remove the pressure valve assembly. Account for

the O-ring.

FS253

5. Using IFP Installation/Location Tool (p/n 0644-

348), remove the floating piston.

! 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 Inflation Needle (p/n
0744-020). 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.

9-146

FS254

6. 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.

7. Items to replace:

A. 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 Floating Piston Installation/Location Tool (p/n

0644-402) to 5.80 in.

FS255

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

FS256

3. Install floating piston tool onto floating piston;

then press floating piston into shock body 5.80 in.

4. Install the pressure valve assembly and tighten to

2.1-2.5 kg-m (15-18 ft-lb).

FS253

5. Fill shock body with lightweight synthetic Shock

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

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9

FS257A

6. With the bearing assembly positioned at the top of

the shock rod, install the shock rod/piston assem-

bly into body; then with the top of the shock body

and rod covered with a shop towel, tap the top of

the rod eyelet with a soft hammer.

„NOTE: Ensure that the piston/valve stack is com-
pletely submerged in shock oil.

FS258

„NOTE: Tapping the eyelet will allow air to escape
from the valve stack/piston assembly.

7. While holding up on the eyelet, thread the bearing

assembly  into the body.

FS259A

8. Using a 1-in. wrench, tighten the bearing assem-

bly.

FS252

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

Pressurizing Rebuildable Shocks sub-section).

FS251

10. Install the valve screw (with O-ring) into the pres-

sure valve assembly.

FS253

11. Test operation of the shock.

„NOTE: Shock should feel soft on compression;
constant on rebound.

9-148

FS080

INSTALLING

1. Place the shock into position on the snowmobile.

2. Secure with existing hardware. Tighten securely.

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 pressure valve assem-

bly on the bottom of the shock. Discharge all the

pressure from the shock using the Inflation Needle

(p/n 0744-020). Open the valve in filler handle

until all pressure is released.

FS081

FS052

FS053

2. Using a 1-in. wrench, loosen the bearing assembly

and remove the shock rod and valve assembly

from the shock body.

FS054

! 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 Inflation Needle (p/n
0744-020). 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.