Snowmobile Arctic Cat (2004 year). Instruction - part 145

 

  Index      Snowmobiles / ATV     Snowmobile Arctic Cat - instruction 2004 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  143  144  145  146   ..

 

 

Snowmobile Arctic Cat (2004 year). Instruction - part 145

 

 

9-96

1. Inspect all front arm weldments for cracks or

unusual bends.

2. Closely inspect all tubing for cracks or unusual

bends.

3. Inspect the bearings, bushings, and front arm spac-

ers for wear or damage.

4. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock
shaft enters the shock body.

5. Inspect the shock absorber eyelet welds (at each

end) for any cracks, signs of separation, or for
unthreading.

6. Inspect the shock absorber and reservoir hoses (on

models with remote adjuster) for damage.

INSTALLING

1. On models with a remote reservoir, place the

remote reservoir into position making sure the
hose is directed to the left-side of the skid frame.
Secure with clamps.

FS045

2. Install the axle into the lower shock eyelet bushing

assembly. Apply grease to the axle; then install the
spacers.

3. Place the shock mount axle into position on the

skid frame making sure the spacers and washers
are properly positioned. Secure with a cap screw,
washers, and new lock nut. Tighten to 4.2 kg-m
(30 ft-lb).

FC177

4. Position the front arm with spacers into the mount-

ing brackets. Secure with cap screws and lock
nuts. Tighten to 4.2 kg-m (30 ft-lb).

FC175

5. Secure the upper shock eyelet and serrated axle in

the appropriate mounting hole of the front arm
(standard arm mounting position). Secure with a
cap screw and lock nut. Tighten to 4.2 kg-m (30 ft-
lb).

FC174

6. Secure the limiter straps with cap screws, washers,

and lock nuts. Tighten to 1.1 kg-m (8 ft-lb).

FC173

„

NOTE: On models with a remote reservoir,

secure the shock absorber hose to the left upper
arm and slide rail using cable ties. Pull the cable
ties tight to prevent the hose from sliding. Com-
press the front arm to assure the hose does not
interfere with the suspension.

9-97

9

0738-233

Rear Shock Absorber 

and Shock Links

„

NOTE: Before removing the skid frame by using

the Rear Suspension Spring Tool (p/n 0144-311),
remove the spring from the adjusting cam.

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

„

NOTE: When removing center components from

the skid frame, it is advisable to loosen all cap
screws/lock nuts from one side of the slide rail to
make removing easier.

DISASSEMBLING

1. Disengage the shock absorber at the upper eyelet

and remove the shock absorber. Account for a
sleeve, cap screw, lock nut, and bushings.

FC170

AG665D

2.  Disengage the shock absorber at the lower eyelet.

Account for washers, link axles, bushings, shock
sleeve, cap screw, and a lock nut.

FC188

3. Note the hole location for assembling purposes;

then remove the cap screws and flat washers
securing the spring slides to the rails. Account for
slide blocks.

! CAUTION

Care must be taken when removing the spring
from the adjusting cam or damage or injury
could result.

9-98

FC158

4. Note the hole location for assembling purposes;

then remove the cap screw and lock nut securing
the pivot assembly to the slide rails.

5. Tap the shock pivot assembly forward until it

clears the mounting brackets; then lift the assem-
bly upward until the shaft clears the rails.

FC186

„

NOTE: Lay components out in order as they are

removed.

6. With the pivot assembly removed, account for the

two spacers, an axle, and the pivot bracket.

FC187

„

NOTE: Using Idler Wheel Puller Kit (p/n 0644-

400), remove the idler wheel from the side from
which the cap screw must be removed.

FC157

7. Noting the hole location for assembling purposes,

remove the cap screw, lock nuts, and washers
securing the shock rod links to the rear arm of the
skid frame. Account for a spacer and two link
axles.

FC171

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Clean shock pivot and idler wheel axle in part-

cleaning solvent. Dry with compressed air.

2. Clean the idler wheel bearings with a clean cloth.

3. Closely inspect the torque link arm and axles for

wear, bends, or damaged splines at either end.

4. Inspect the idler wheels for signs of cracking,

wear, or outer rubber separation from plastic
wheel.

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

inspect for any signs of binding or roughness.

6. If a bearing must be replaced, use this procedure.

! WARNING

Always wear an approved pair of safety glasses
when using compressed air.

9-99

9

A. Remove the snap ring.

B. Using a hydraulic press, press the bearing out

the inside of the wheel.

C. Press the new bearing (on its outer race) into

the idler wheel.

AG538D

D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.

AG539D

7. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock
shaft enters the shock body.

8. Inspect the rubber shock bushings located in the

shock absorber eyelets for cracks or deterioration.

9. Inspect the shock absorber eyelet welds (at each

end) for any cracks or signs of separation.

10. 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.

11. 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. Position the shock links in the appropriate holes of

the idler arm brackets (see Chassis and Skid Frame
Mounting Locations in this section). Place a
spacer between the center of the brackets; then
place a flat washer on the cap screw. Insert the link
axles into the upper shock link eyelets; then insert
the cap screw with washer through the eyelets.
Secure with a cap screw, washer, and lock nut.
Tighten to 4.2 kg-m (30 ft-lb).

FC171

2. Install the idler wheel removed in disassembling.

3. Secure the shock absorber to the idler arm with

bushings, sleeve, lock nut, and a cap screw.
Tighten to 4.2 kg-m (30 ft-lb).

FC170

4. Apply a thin coat of low-temperature grease to the

axle and slide the axle into the shock pivot
bracket. Have equal amounts of the axle exposed
on either side of the bracket tube.

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.

 

 

 

 

 

 

 

Content   ..  143  144  145  146   ..