Snowmobile Arctic Cat (2002 year). Instruction - part 161

9-122

Front Arm Shock 

Absorber

„

NOTE: The skid frame must be removed for this

procedure.

DISASSEMBLING

1. Remove the cap screw and lock nut securing the

upper shock absorber eyelet to the front arm.

Account for a bushing.

AG306

2. Remove the cap screw and lock nut securing the

lower shock eyelet to the front shock bracket.

Remove the shock absorber and account for a

bushing.

AG317

3. Slide the rubber shock boot off the shock absorber.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock

shaft enters the shock body.

2. Inspect the shock absorber eyelet welds (at each

end) for any cracks or signs of separation.

ASSEMBLING

1. Apply a light coat of grease to both bushings and

install the bushings into the shock absorber eye-

lets.

AG318

2. Position the lower shock absorber eyelet into the

crossbrace bracket and secure with a cap screw

and lock nut. Tighten to 3.2 kg-m (23 ft-lb).

3. Position the upper shock absorber eyelet into the

front arm bracket and secure with a cap screw

(coated with red Loctite #271) and lock nut.

Tighten to 3.2 kg-m (23 ft-lb).

„

NOTE: Do not over-tighten the shock cap screws

as the shock eyelets must be free to pivot.

Rear Arm 

Shock Absorber 

And Shock Links

„

NOTE: The skid frame must be removed for this

procedure.

DISASSEMBLING

1. Remove the cap screw and lock nut securing the

lower shock absorber eyelet and shock links to the

pivot tube bracket. Account for the two shock link

axles.

AG314

9-123

9

2. Remove the cap screw and lock nut securing the

upper shock absorber eyelet to the rear arm

bracket. Remove the shock absorber.

AG309

3. Remove the cap screw and lock nut securing the

shock links to the upper arm bracket. Account for

the spacer, two shock link axles, and washers.

AG310

AG316

INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock

shaft enter the shock body.

2. Inspect the rubber shock bushings located in the

shock absorber eyelets for cracks or deterioration.

3. Inspect the shock absorber eyelet welds (at each

end) for any cracks or signs of separation.

4. Inspect the welds securing the eyelets of the shock

links for cracks or signs of separation. Either weld

the eyelet or replace the shock link assembly.

5. Inspect the axle surfaces for any signs of corro-

sion. If corrosion is found, lightly buff the surface

of the axle with #400 wet-or-dry sandpaper; then

apply a light coat of grease.

ASSEMBLING

1. Apply a thin coat of grease to the upper shock

absorber eyelet. Position the eyelet into the upper

arm bracket and secure with a cap screw and lock

nut. Tighten to 3.2 kg-m (23 ft-lb).

AG309

2. Apply a thin coat of grease to the outer surface of

the shock link axles and slide the axles into the

shock link eyelets.

3. Place the shock link eyelets on each side of the

upper arm bracket and place a spacer into the

bracket. Secure the shock links and spacer to the

upper arm bracket using a cap screw, washers (on

the outside of each eyelet), and lock nut. Tighten

lock nut to 3.2 kg-m (23 ft-lb).

„

NOTE: When installing shock links, the longest

side of the shock eyelet must be positioned toward
the shock absorber.

AG313

9-124

4. Place the lower shock absorber eyelet into the rear

pivot bracket; then place the lower shock link eye-

let with bushings into position and secure the

lower shock link eyelet and the shock absorber to

the rear pivot bracket with a cap screw, two wash-

ers, and lock nut. Tighten to 3.2 kg-m (23 ft-lb).

„

NOTE: Do not over-tighten the shock cap screws

as the shock eyelets must be free to pivot.

AG314

Rear Shock Pivot

„

NOTE: The skid frame must be removed for this

procedure.

DISASSEMBLING

1. Remove the cap screw and lock nut securing the

lower shock absorber eyelet and shock links to the

pivot tube bracket. Account for the two shock link

axles.

AG314

2. Remove the cap screw and flat washer securing

the pivot arm axle to the pivot arm mounting

bracket.

3. Slide the inner axle out of the pivot arm bracket far

enough to remove the rear shock pivot and account

for a spacer axle.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all shock pivot components.

2. Inspect all axles for wear or damage.

3. Inspect idler wheel and hub for cracks or damage.

4. Inspect rear pivot for damage.

ASSEMBLING

1. Align the rear shock pivot with the spacers, idler

wheels, and washers installed between the pivot

arm brackets; then slide the pivot axle through the

brackets.

2. Place the lower shock absorber eyelet into the rear

pivot bracket; then place the lower shock link eye-

lets with bushings into position and secure the

lower shock link eyelets and the shock absorber to

the rear pivot bracket with a cap screw, two wash-

ers, and lock nut. Tighten to 3.2 kg-m (23 ft-lb).

„

NOTE: Do not over-tighten the shock cap screws

as the shock eyelets must be free to pivot.

Center Inner

Idler Wheels

„

NOTE: The skid frame does not have to be

removed for this procedure.

REMOVING

1. Remove the cap screws and flat washers securing

the idler wheels and spring slides to the center

idler wheel brackets.

AG403

2. Slide the inner axle out of the center idler wheel

brackets and remove the idler wheels. Account for

two spacer axles and six washers.

9-125

9

INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect each idler wheel and plastic hub for cracks

or damage.

2. Rotate the idler wheel bearings (by hand) and

inspect for binding or roughness.

INSTALLING

1. Position the idler wheels with spacers and spacer

washers (one on each side of idler wheel) between

the center idler wheel brackets.

2. Slide the inner axle through the idler wheel brack-

ets, idler wheels, spacers, and spacer washers.

3. Place the spring slides onto the springs and idler

wheel brackets; then secure with two flat washers

and cap screws (coated with red Loctite #271).

Tighten to 2.4 kg-m (17 ft-lb).

AG403

Slide Rail

„

NOTE: The skid frame must be removed for this

procedure.

REMOVING

„

NOTE: When it is necessary to replace one or

both slide rails, it is recommended that one slide
rail be removed at a time. The remaining slide rail
will then hold the crossbraces and brackets in
their correct assembly order. This method is much
quicker than to completely disassemble the entire
skid frame.

1. Remove the cap screw, washer, and lock nut

securing the end cap to the slide rail. Remove the

end cap from the slide rail.

AG297D

2. Remove the four cap screws securing both front

crossbraces between the slide rails; then remove

the crossbraces.

AG301

3. Remove the push nuts and pins securing the rubber

shock pads; then remove the shock pads.

4. Remove the cap screw and flat washer securing

the outer idler wheel to the front arm bracket.