Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 161

9-157

9

FS165

12. Install the nylon pellet by gently tapping it with a

plastic mallet.

FS166

13. Test the shock for proper operation.

14. Using compressed air, blow all oil from the holes

in the bearing cap.

FS167

15. Lubricate the seal on the air chamber with Fox

Float Fluid (p/n 4639-012).

FS168

16. Slide the air chamber onto the shock body.

FS169

17. Add 1 cc of Fox Float Fluid (p/n 4639-012) into

the chamber.

FS170

18. Thread the air chamber into the end cap until

hand-tight.

FS171

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„NOTE: Prior to installing the air chamber, make
sure the end cap O-ring is properly positioned in
the chamber.

19. Invert the shock and secure by the end cap to

assure the air chamber is tight.

FS172

20. Using a hand pump, inflate the air chamber to

60 psi for the M-Series models or 65 psi for the

Crossfire/F-Series models.

FS173

21. Install the valve cap.

FS174

Servicing Fox Zero Pro 

Shock Absorbers 

This procedure shows the proper methods for disas-

sembling, rebuilding, and assembling the pro shock

absorbers with no external damping adjustments.

„NOTE: Some illustrations and photographs used
in the following sub-sections are used for clarity
purposes and are not designed to depict actual
conditions.

DISASSEMBLING

1. Remove the steel sleeve and polyurethane bush-

ings from the eyelets on both ends of the shock.

2. Clean the entire shock assembly with soapy water.

Dry the shock assembly with compressed air.

„NOTE: If compressed air is not available, use
clean towel to dry the shock assembly.

3. Clamp the body eyelet of the shock securely in

vise with shaft side up.

4. Remove the button-head screw from the nitrogen

valve in the shock body.

! WARNING

Before starting, read through all of these instruc-
tions first to become familiar with the procedure.
Make sure the work area is clean and all of the nec-
essary tools are available. These shocks contain
high pressure nitrogen gas. Always use proper
safety equipment such as latex gloves and safety
glasses when working on shock absorbers.

! CAUTION

Use a soft-bristle brush to remove as much dirt and
debris as possible. Do not pressure wash the shock
as this can force water and debris inside causing
damage to the seals.

! WARNING

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

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9

FS040

5. Insert the needle squarely into center of the nitro-

gen valve to release the pressure.

FS016

6. When the shock is fully discharged, pull the needle

away from the reservoir in a straight, smooth

motion.

7. Loosen (but do not remove) the bearing bleed

screw.

FS013

8. Loosen and unscrew the bearing assembly from

the shock body.

FS006

9. Remove the shaft assembly from the body tube

and place it on a clean, lint-free paper towel.

10. Remove the shock from the vise and pour shock

oil from body tube into a proper disposal con-

tainer. DO NOT REUSE OLD SHOCK OIL.

11. Clamp the body cap of the shock securely in vise

with the open end of the body tube pointing up. 

12. Loosen and remove the nitorgen valve from the

body.

FS014

13. Remove the shock body from the vise; then invert

the shock body and place it on a folded shop towel

open end down.

14. Using compressed air (NEVER USE HIGH

PRESSURE NITROGEN), insert the air gun noz-

zle into the nitrogen valve port and blow the IFP

out of the shock body and onto the folded shop

towel.

FS012

! WARNING

Point the nitrogen valve away from face and body to
avoid injury when discharging or charging the
shock.

9-160

15. Clean the body tube, reservoir tube, and the IFP

with solvent. Dry with compressed air in a well

ventilated area.

16. Set body assembly aside on a clean, lint-free

towel.

17. Clamp the shaft eyelet securely in vise with the

piston end up.

18. Remove the piston lock nut from the end of the

shaft.

FS008

19. Hold the tip of a screwdriver against the end of

shaft; then hold the piston assembly under the top-

out plate and lift upwards. 

FS009

„NOTE: Keeping the components in order is criti-
cal for proper performance of the shock absorber.
Doing steps 20-21 properly ensures that proper
order is kept. 

20. Slide the piston assembly onto the shaft of the

screwdriver. Pull the screwdriver away from shock

shaft while supporting the piston assembly and set

this on a clean, lint-free towel.

FS010

21. Slide bearing assembly off of shaft.

22. Remove the bleed screw from the bearing and set

them both on a clean, lint-free towel.

REBUILDING

1. Using a pair of snap ring pliers, remove the snap

ring from the bearing housing. Using fingers,

remove the FIST scraper from the housing. Using

a scribe, remove the O-ring from the inside of the

FIST scraper by “spearing” the seal with the point

of the scribe and pulling it out.

FS011

2. Using a scribe, remove the U-cup wiper and O-

ring seals from the bearing housing. 

3. Thoroughly clean the FIST bearing, bearing hous-

ing, and piston assembly with solvent. Dry with

compressed air in a well ventilated area.

! CAUTION

Use care when passing the bearing over the shaft
threads not to scratch the inside of the bearing
assembly.

! CAUTION

Care must be taken when using a scribe to remove a
seal. Always spear the seal with the point of the
scribe. Do not attempt to wedge the scribe behind
the seal as this could cause damage to the seal
groove and compromise the performance of the
shock.