Snowmobile Arctic Cat (2008 year). Manual - part 145

7-140

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
completely 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.

7-141

7

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 Nee-

dle. Open the valve in filler handle until all pres-

sure 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. 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.

7-142

FS055

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

container.

FS056

4. Using a 3/16-in. Allen wrench, remove the set

screw.

FS057

FS058

„NOTE: Account for a set screw, 5/16-in. ball,
spring, spring rod, and a 1/4-in. ball.

FS059

5. Remove the pressure valve assembly. Account for

the O-ring.

FS060

6. Using Floating Piston Removal Tool, remove the

floating piston.

FS061

7. Items to inspect:

A. Shock shaft for straightness, nicks, or burrs.

B. Shaft bearing assembly — 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.

7-143

7

F. Valves for kinks or waves.

G. Rubber damper (ski shocks only) for chipping,

cracking, or being missing.

8. Items to replace:

A. Floating piston O-ring.

B. Shock shaft bearing assembly if any signs of oil

leaks or damage.

C. Any part worn or damaged.

„NOTE: For shaft eyelet replacement, see Shaft
Eyelet sub-section.

ASSEMBLING

1. Set Floating Piston Installation/Location Tool 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 floating piston tool onto floating piston;

then press floating piston into shock body 5.90 in.

FS065

FS066

4. Install the pressure valve assembly and tighten to

15-18 ft-lb.

FS060