Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 162

9-161

9

4. Using a scribe, remove the O-ring seal from the

IFP.

5. Install the new, well lubricated O-ring into the

FIST bearing. Check to make sure the O-ring is

properly seated and is not twisted. 

„NOTE: To aid in proper seating of the O-ring, it
may be advisable to use a soft, blunt object (non-
writing end of a pen, etc.) to push it in.

6. Install the new, well lubricated O-rings into the

bearing housing making sure the shaft O-ring is in

the groove next to the DU bushing and that the O-

rings are properly seated and not twisted. It may

be advisable to use a soft, blunt object to push it in.

7. Install the new U-cup seal into bearing. U-cup

should be installed so the cupped end is facing the

DU bushing inside of bearing. Check to make sure

seal is properly seated. It may be advisable to use a

soft, blunt object to push it in. 

8. Install FIST bearing into housing. Check for

proper orientation of the FIST bearing. The

stepped side of the FIST bearing should be visible. 

9. Using a pair of snap ring pliers, install the snap

ring into the bearing housing. Check for proper

orientation of the snap ring. The flat side of the

snap ring should be visible. Check to make sure

the snap ring is properly seated.

FS007

10. Install the new, well greased O-ring onto the IFP.

11. Replace the bearing bleed screw O-ring. 

ASSEMBLING

1. Clamp shaft eyelet securely in vise and place a

seal tool on end of shaft. 

2. Lubricate the bearing assembly seals with an

assembly lube. Slide the bearing assembly onto

shaft with the FIST bearing facing the eyelet. This

should be done in a single smooth motion to avoid

damaging the seals.

3. Hold the piston assembly from underneath the top-

out plate and place the end of the screwdriver onto

the end of the shock shaft. Slide the piston assem-

bly onto the shaft end. Check to make sure the pis-

ton assembly is seated properly and install the

piston lock nut. Tighten nut to 2.5 kg-m (18 ft-lb).

Remove shaft assembly from vise and set it aside

on a clean, lint-free paper towel.

FS008

4. Clamp the body of the shock securely in the vise

with the open end of the body facing up.

5. Lubricate the IFP O-ring with assembly lube and

wrap a new piston ring around it.

6. Insert the IFP into the shock body (with the dished

side facing up toward the open end of the shock

body) to just below the bearing threads. 

FS015

7. Using Floating Piston Installation/Location Tool

(p/n 0644-402), install the floating piston while

using the inflation needle to vent the shock body.

„NOTE: Refer to the 2007 Rebuildable Shock
Specifications sub-section in this section. 

„NOTE: Depth is measured from the edge of the
body opening to the outside edge of the IFP (not
the center depression of the IFP).

8. Lubricate the O-ring on the nitrogen valve with

assembly lube and thread it into the body. Tighten

securely.

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FS014

9. Fill the body tube with oil to the bottom of the

bearing threads. Wrap the new piston band around

the piston making sure the rounded edges face out.

Insert the shaft assembly into the body tube.

Slowly push shaft into body until piston assembly

is approximately 12.7 mm (0.5 in.) below the oil

surface. 

10. Slowly stroke the shaft assembly up and down

over about a 1-inch range two to three times being

very careful not to pull the piston assembly out of

the oil. 

„NOTE: At this point, there should be no air bub-
bles rising from the piston assembly.

11. Top off the shock body with oil and slowly pull the

shaft up until the piston assembly is about in the

middle of the bearing threads.

12. Holding the shaft in that position, slide the bearing

assembly down the shaft and start threading it into

the body by hand. Oil should flow out of the bear-

ing bleed hole.

13. As the bearing assembly is being threaded down, it

will contact the damping piston assembly and pull

it down into the shock body with it. As the bearing

is being threaded in from this point, be sure the

damping piston assembly stays in contact with the

bearing.

14. When the bearing is threaded all the way down,

thread the bleed screw into the bearing assembly

and tighten it securely.

FS013

15. Tighten the bearing assembly into the body.

FS006

16. Push the shaft all the way down until the eyelet

lightly contacts the FIST scraper on the bearing

assembly. It should go all the way down without

any feeling of contact or interference. 

„NOTE: At this point, DO NOT attempt to pull the
shaft up out of the body.

17. If there is any interference while pushing the shaft

into the body, the IFP is in the wrong location.

18. If there is no interference, proceed to step 19.

19. Maintain the shock in the vise.

20. Make sure the nitrogen valve is directed outward.

21. Insert the needle squarely into the center of the

nitrogen valve (taking care that the valve is

directed away from face and body) and pressurize

the reservoir to 200 psi. The shock shaft should be

fully extended from the pressure before the final

pressure reading is taken. Continue charging while

pulling the reservoir away from the needle using a

smooth, straight motion. Keep the reservoir as

straight as possible to prevent the needle from

bending. As the reservoir and needle separate, a

“popping” sound should be heard.

! WARNING

If there is interference, unthread the bearing assem-
bly from the body and repeat steps 4-16 of Assem-
bling. Failure to repeat the steps and rid the shock of
the interference may cause damage to the shock
resulting in improper shock performance and could
cause operator injury.

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9

FS016

22. Install the button-head screw into the nitrogen

valve.

FS040

23. Clean all oil residue from the shock and reservoir

with solvent and dry with compressed air in a well

ventilated area. 

24. Install the polyurethane bushings and steel sleeves

into the eyelets.

Shaft Eyelet

REMOVING

1. Using Shock Rod Clamping Tool (p/n 0744-021)

to prevent damage to the shaft surface, place the

shock shaft into a vise.

2. Heat the shaft eyelet with a torch to soften the

Loctite.

AG260

„NOTE: The eyelet must be heated up to 300° for
the Loctite to soften.

3. Using a wrench, unscrew the eyelet from the shaft.

AG261

„NOTE: With the eyelet removed, inspect the bot-
tom-out bumper for cracks or wear.

INSTALLING

1. Clean shaft threads and eyelet threads. 

2. Apply red Loctite #271 to both threads, install the

eyelet, and tighten securely.

Pressurizing 

Rebuildable Shocks

To pressurize the gas shock absorber, a regulator sys-

tem and a nitrogen tank will be needed.

! WARNING

Charge the shock using nitrogen gas only. DO NOT
CHARGE WITH ANY OTHER TYPE OF GAS. Doing so
will compromise the performance of the shock and
may be EXTREMELY DANGEROUS.

9-164

AG271

„NOTE: Before inserting the needle into the blad-
der, lubricate the needle with light oil to make
installation easier.

1. Insert the Inflation Needle (p/n 0744-020) into the

shock bladder; then open the valve on the filler

handle.

FS079

2. Turn the nitrogen tank valve open and slowly

rotate the regulator T-handle inward until the

gauge reads 200 lb of pressure; then close filler

valve and remove inflation needle.

3. Install the screw into the bladder housing and

tighten securely.

4. With the reservoir pressurized, push down on the

shock shaft until it nearly bottoms and release it.

The shaft should return to its extended position

smoothly.

„NOTE: If a soft spot or a mushy area is felt as the
shaft is pushed down, this would indicate air in the
shock body. If there is air in the shock body, dis-
charge the reservoir gas pressure. Disassemble
the shock to the point that the “filling with oil” and
the “bleeding air” procedures can be redone.
Assemble and repeat the pressurizing procedure.
To test the shock absorber for nitrogen gas leaks,
submerge in water.

Troubleshooting Track

! WARNING

Never have a nitrogen bottle in the area without hav-
ing it chained or secured. If the bottle should tip over
and the regulator break off, the gas inside it is under
1800 lb of pressure and personal injury may result.

! WARNING

Always rotate the regulator T-handle to its loose
position each time when finished using the system.
Each time before the nitrogen tank valve is opened,
check to make sure the regulator T-handle is turned
out. When opening the nitrogen tank valve, never
stand in front of the regulator in case there should
be a problem.

Problem: Track Edge Frayed — Drive Lugs Worn

Condition

Remedy

1. Track alignment adjusted incorrectly

1. Align — replace track

Problem: Track Worn Adjacent to Outer Drive Lugs

Condition

Remedy

1. Track tension adjusted incorrectly

1. Adjust track tension

2. Rear idler wheels dirty — damaged

2. Clean — replace idler wheels

Problem: Track Ratchets — Slaps Tunnel

Condition

Remedy

1. Track tension adjusted incorrectly (too loose)

1. Adjust track tension (tighten)

2. Drive sprockets misaligned — damaged

2. Align — replace sprockets

Problem: Wear-Strip Wear Excessive

Condition

Remedy

1. Slide rail bent — broken — damaged

1. Repair — replace slide rail

2. Track alignment adjusted incorrectly

2. Adjust track alignment