Snowmobile Arctic Cat (2002 year). Instruction - part 173

9-170

13. Using Shock Retaining Blocks (p/n 0644-142) to

hold the shock in place and using an adjustable

wrench, tighten the end cap securely.

AP016DA

14. Apply a light coat of oil on the bladder housing O-

ring; then install the brass bladder housing into the

lower end cap. Tighten securely.

AP014

15. Pressurize the shock (see Pressurizing Rebuildable

Shocks section). After shock has been pressurized,

install screw into bladder housing. Tighten

securely.

16. Install shock eyelet bushings and axle.

Servicing Front Arm 

Quick-Adjust Shock

REMOVING

1. Remove the shock from the snowmobile.

„

NOTE: When removing the shock from the snow-

mobile, it will be necessary to disconnect the
adjuster assembly. Before disconnecting the
adjuster, the adjustment knob must be turned
completely open (counterclockwise) so there is no
pressure on the line. To prevent oil spillage, place
a protective cap on the hose end.

2. Wash the shock body in parts-cleaning solvent;

then dry with compressed air to remove sand and

dirt.

AG807

DISASSEMBLING

1. Using the Shock Retaining Blocks (p/n 0644-142),

place the remote reservoir in a vise.

AG808

2. Remove the valve screw from the pressure valve.

! WARNING

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

! WARNING

Before any work can be 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 Shock
Inflation Needle (p/n 0644-158). Open valve until all
pressure is released. Failure to do this may cause
personal injury.

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9

AG809

3. Discharge all pressure from the remote reservoir

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

Open the valve in the filler handle until all pres-

sure is released.

AG810

4. Reattach the adjustment knob assembly to the

shock adjuster hose.

AG811

5. Push the remote reservoir end cap in; then use a

sharp tool to remove the circlip. Remove the

remote reservoir end cap.

AG812

AG813

6. Secure the shock body eyelet in a vise; then loosen

the shock end cap and carefully remove the shock

rod with valving assembly.

„

NOTE: If the shock body turns with the upper

end cap, the shock body can be removed from the
lower end cap; then remove the outer sleeve and
place the shock body in the shock blocks. Remove
the upper end cap.

AG814

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AG815

„

NOTE: If for some reason the piston must be

removed from the shock shaft, it must be installed
with the “Rebound Side” located next to the lock
nut of the shock shaft.

„

NOTE: Do not remove the lock nut from the bot-

tom of the shock rod as it is very important the
valving on either side of the piston stay in its
proper position. If shock valving must be removed
for cleaning, remove all valving as a complete
assembly and place on a 5/16 x 3-in. cap screw to
keep in the proper order. Note which side is the
top side for assembly purposes.

7. Remove the spiral retaining ring from the shock

body; then remove the outer threaded sleeve.

AG816

AG817

8. Pour out the excess oil from the shock body.

9. Using a long needle-nose pliers, remove the float-

ing piston from the remote reservoir; then pour out

the excess oil from the remote reservoir.

AG818

AG819

10. Clean the shock body, reservoir, and the outer

threaded sleeve with parts cleaner.

DISASSEMBLING/CLEANING/

ASSEMBLING ADJUSTER BODY

1. Disconnect the quick coupler.

2. While securing the adjuster body in a vise with

Shock Retaining Blocks (p/n 0644-142), remove

the adjuster end cap; then remove the Allen-head

screw from the center of the floating piston.

AG820

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9

AG821

3. Using a long needle-nose pliers, remove the float-

ing piston from the adjuster assembly.

AG822

4. Pour out the oil from the adjuster body.

5. Clean all components thoroughly; then use com-

pressed air to dry.

6. Using the retaining blocks, secure the adjuster

body in a vise.

7. Pour oil into the adjuster body until it reaches the

bottom of the threads; then using a suitable tool,

push in on the spring-loaded valve in the coupler

assembly to remove any air in the coupler fitting

and hose. Add oil to reach the bottom of the

threads. Allow time for air bubbles to dissipate.

AG823

8. Adjust the piston location tool (see Rebuildable

Shock Piston Depth Chart in this section).

AG824

9. Using a good low-temperature grease, lightly

grease the O-ring of the floating piston.

10. Using a long needle-nose pliers, insert the floating

piston into the adjuster body until the piston is

flush with the top of the body.

11. Using the piston location tool as a handle, push the

piston down into the adjuster body until the adjust-

ment stop of the tool comes in contact with the

adjuster body. The piston should now be located

correctly.

AG825

12. Install the Allen-head screw with a new O-ring

into the floating piston; then tighten securely.

! WARNING

When using compressed air, always wear a good
pair of safety glasses.