Snowmobile Arctic Cat (2004 year). Manual - part 160

9-156

6. Install the reservoir end cap and O-ring down into

the reservoir approximately 2.5 cm (1 in.). Install
the retainer ring making sure it is firmly in place.

AP011

7. Grasp the bladder housing with a pliers and pull it

up into place against the retainer ring.

8. Slowly pour oil into the shock body until it is 1/4

in. from the top of the shock body. Again, allow
five minutes to elapse before proceeding.

9. Space the bottom edge of the bearing cap approxi-

mately 1/2 to 1 in. away from the piston assembly.

10. To install the shock rod, align the valve piston

wear ring end gap with the low-speed orifice cut-
away positioning the cutaway so it faces the
upward angle of the shock body which will allow
air to escape.

AG860

11. Compress the piston ring into position with fingers

and slowly start the piston assembly down into the
shock body.

AG853

12. Give the end of the shock rod a few light taps with

the palm of the hand to help release air bubbles
from the piston valves.

„

NOTE: Be careful not to damage the piston ring

and watch that the piston ring ends are overlapped
and in place as the piston is installed.

13. Install the end cap very slowly to allow excess air

and oil to come out the threads; then using a 1-in.
wrench, tighten the bearing cap firmly down in
place. Do not push down on the shock shaft until
the reservoir has been pressurized. Pressurize the
reservoir.

AG852

14. Discharge all pressure from the shock reservoir

using Shock Inflation Needle (p/n 0644-158).
Open valve in filler handle until all pressure is
released.

15. 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.

16. Measure the piston depth from the top of the reser-

voir body to the top of the floating piston. Mea-
surement should be within specification (see
Rebuildable Shock Piston Depth Chart in this sec-
tion). If measurement is not correct, pour 1 inch of
shock oil on top of the piston. Remove the Allen-
head screw; then move the piston to the proper
depth and install Allen-head screw with O-ring.

9-157

9

17. Install the reservoir end cap and O-ring down into

the reservoir approximately 2.5 cm (1 in.). Install
the retainer ring making sure it is firmly in place.

18. Pressurize the reservoir.

19. Install the shock mounting bushings and bearings

in eyelets. 

Bearing Cap

and Shaft Seal

REMOVING AND DISASSEMBLING

1. With shaft assembly removed from shock body,

clamp shaft eyelet in vise and remove the lock nut.

AP028

2. Lift the piston valve assembly.

„

NOTE: When removing the piston and valve

plates from the shock shaft, place the piston
assembly on a 5/16 x 3-in. cap screw and secure
with a nut to keep the assembly in its proper order.

AP032

3. Remove the bearing cap (on front arm adjuster

shocks, remove the adjuster piston and a spacer
washer first).

4. Remove the outer plastic wiper; then remove the

inner rubber wiper from the bearing cap.

AG257

5. Using a small paper clip bent on one end, remove

the inner O-ring.

AG258

ASSEMBLING AND INSTALLING

1. Install new O-ring and inner rubber wiper into the

shaft bearing cap; then install outer plastic wiper.

AG259

2. Inspect the shoulder or step of the shaft for sharp

edges or a burr. Smooth up with #400 grit sand
paper or emery cloth.

3. Put Bearing Cap Installation Tool (p/n 0644-268)

over the threaded end of the shaft.

9-158

AP114DA

4. Put a small amount of light grease on the seal and

slide the bearing cap over the tool and onto the
shaft.

AP115DA

5. On a front arm adjuster shock, install the spacer

washer on shaft and install adjuster piston in the
same manner as bearing cap; then remove the
installation tool.

6. Install piston valve assembly. Tighten the self-

locking nut to 2.1-2.8 kg-m (15-20 ft-lb).

AG280

Shaft Eyelet

REMOVING

1. Using Shock Rod Clamping Tool (p/n 0644-277)

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

INSTALLING

1. Clean shaft threads and eyelet threads. 

2. Apply red Loctite to both threads, install the eye-

let, and tighten securely.

9-159

9

Ski Shocks 

Bottom-Out Bumper

Bottom-out bumper can be replaced by removing
shock eyelet or by removing piston valving assembly
and bearing cap.

Pressurizing

Rebuildable Shocks

To pressurize the gas shock absorber, a regulator sys-
tem and a nitrogen tank will be needed.

AG271

„

NOTE: Before inserting the needle into the blad-

der, lubricate the needle with light oil to make
installation easier.

1. Insert the Shock Inflation Needle (p/n 0644-158)

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.

„

NOTE: On remote reservoir shocks, use a needle

nose vise grips to hold the bladder housing to
keep the end cap from pushing into the reservoir
when inserting the inflation needle.

AG851

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.

! WARNING

Never have a nitrogen bottle in the area without
having 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.