Snowmobile Arctic Cat (2004 year). Instruction - part 156

 

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Snowmobile Arctic Cat (2004 year). Instruction - part 156

 

 

9-140

2004 VALVE STACKS

Ski Shock (p/n 1703-520)

Mountain Cat 800/900

Compression:

Rebound:

10.

1.300 x .008

1.

1.250 x .006

9.

1.100 x .006

2.

1.250 x .008

8.

.900 x .010

3.

1.250 x .006

7.

.800 x .010

4.

1.250 x .008

6.

1.250 x .008

5.

1.100 x .008

5.

1.250 x .006

6.

1.000 x .010

4.

1.100 x .008

7.

1.000 x .010

3.

1.000 x .010

8.

.900 x .010

2.

.900 x .010

9.

.800 x .010

1.

.800 x .010

Piston Depth 5.940 in./Piston Orifice .093 in.

Ski Shock (p/n 1703-520)

King Cat 900

Compression:

Rebound:

9.

1.250 x .006

1.

1.300 x .008

8.

1.250 x .008

2.

1.100 x .006

7.

1.250 x .006

3.

.900 x .010

6.

1.250 x .008

4.

.800 x .010

5.

1.100 x .008

5.

1.250 x .008

4.

1.000 x .010

6.

1.250 x .006

3.

1.000 x .010

7.

1.100 x .008

2.

.900 x .010

8.

1.000 x .010

1.

.800 x .010

9.

.900 x .010

10.

.800 x .010

Piston Depth 5.940 in./Piston Orifice .093 in.

Ski Shock (p/n 1703-449)

Firecat (STD)

Compression:

Rebound:

8.

1.300 x .006

1.

1.250 x .006

7.

.800 x .006

2.

1.250 x .006

6.

.700 x .015

3.

.900 x .006

5.

1.250 x .008

4.

1.250 x .010

4.

1.100 x .010

5.

1.100 x .010

3.

1.000 x .010

6.

1.000 x .010

2.

.900 x .010

7.

.900 x .010

1.

.800 x .010

8.

.800 x .010

Piston Depth 7.500 in./Piston Orifice .120 in.

Remote Reservoir Ski Shock

(p/n 1703-484-R/1703-485-L)

Firecat Sno Pro

Compression:

Rebound:

9.

1.300 x .008

1.

1.250 x .008

8.

1.100 x .008

2.

1.100 x .010

7.

.900 x .010

3.

1.000 x .010

6.

.700 x .012

4.

.900 x .010

5.

1.250 x .008

5.

.800 x .010

4.

1.100 x .008

6.

.620 x .094

3.

1.000 x .008

Backup washer

2.

.900 x .008

1.

.800 x .008

Piston Depth 2.000 in./Piston Orifice .093 in.

Front Arm Shock (p/n 1704-150)

Mountain Cat 800 EFI/900/900 EFI/

King Cat 900

Compression:

Rebound:

6.

1.300 x .012

1.

1.250 x .010

5.

1.100 x .012

2.

1.100 x .010

4.

1.000 x .012

3.

1.000 x .010

3.

.900 x .010

4.

1.000 x .010

2.

.800 x .010

5.

.900 x .010

1.

1.250 x .010

6.

.800 x .010

Piston Depth 4.260 in./Piston Orifice .059 in.

Front Arm Shock (p/n 1704-142)

Sabercat (STD)

Compression:

Rebound:

5.

1.300 x .008

1.

1.250 x .010

4.

1.100 x .008

2.

1.100 x .010

3.

1.000 x .010

3.

1.000 x .010

2.

.900 x .010

4.

.900 x .010

1.

.800 x .010

5.

.800 x .010

Piston Depth 4.260 in./Piston Orifice .093 in.

Front Arm Shock (p/n 1704-116)

Firecat (STD)

Compression:

Rebound:

5.

1.300 x .010

1.

1.250 x .010

4.

1.100 x .010

2.

1.100 x .010

3.

1.000 x .010

3.

1.000 x .010

2.

.900 x .010

4.

.900 x .010

1.

.800 x .010

5.

.800 x .010

Piston Depth 4.260 in./Piston Orifice .093 in.

Front Arm Shock (p/n 1704-140)

Firecat Sno Pro

Compression:

Rebound:

6.

1.300 x .012

1.

1.250 x .012

5.

1.100 x .012

2.

1.250 x .010

4.

1.000 x .012

3.

1.100 x .010

3.

.900 x .010

4.

1.000 x .010

2.

.800 x .010

5.

1.000 x .010

1.

1.250 x .010

6.

.900 x .010

Top out washer

7.

.800 x .010

Backup washer

Piston Depth 2.00 in./ Piston Orifice .055 in.

Rear Arm Shock (p/n 1704-153)

Mountain Cat 800 EFI/900/900 EFI

Compression:

Rebound:

7.

1.300 x .010

1.

1.250 x .010

6.

1.100 x .010

2.

1.250 x .015

5.

.900 x .004

3.

1.250 x .010

4.

1.250 x .010

4.

1.250 x .010

3.

1.100 x .015

5.

1.100 x .010

2.

1.000 x .015

6.

1.000 x .010

1.

.900 x .010

7.

.900 x .010

8.

.800 x .010

Piston Depth 5.800 in./Piston Orifice .039 in.

Rear Arm Shock (p/n 1704-154)

King Cat 900

Compression:

Rebound:

7.

1.300 x .010

1.

1.250 x .015

6.

1.100 x .010

2.

1.250 x .015

5.

.900 x .006

3.

1.250 x .015

4.

1.250 x .010

4.

1.100 x .015

3.

1.100 x .012

5.

1.100 x .015

2.

1.000 x .012

6.

1.000 x .012

1.

.900 x .010

7.

.900 x .012

Piston Depth 5.800 in./Piston Orifice .039 in.

Rear Arm Shock (p/n 0704-852)

Sabercat (STD)

Compression:

Rebound:

6.

1.300 x .008

1.

1.250 x .012

5.

1.250 x .008

2.

1.250 x .012

4.

1.100 x .008

3.

1.100 x .012

3.

1.000 x .008

4.

1.000 x .012

2.

.900 x .008

5.

.900 x .010

1.

.800 x .008

6.

.800 x .010

Piston Depth 5.900 in./Piston Orifice .039 in.

Rear Arm Shock (p/n 1704-139)

Sabercat (EXT)

Compression:

Rebound:

6.

1.300 x .010

1.

1.250 x .015

5.

1.250 x .010

2.

1.250 x .012

4.

1.100 x .010

3.

1.250 x .012

3.

1.000 x .010

4.

1.100 x .010

2.

.900 x .010

5.

1.000 x .010

1.

.800 x .010

6.

.900 x .010

7.

.800 x .010

Piston Depth 5.900 in./Piston Orifice .039

9-141

9

Rear Arm Shock (p/n 1704-117)

Firecat (STD)

Compression:

Rebound:

8.

1.300 x .010

1.

1.250 x .012

7.

1.100 x .008

2.

1.250 x .012

6.

.900 x .010

3.

1.100 x .012

5.

.700 x .004

4.

1.000 x .012

4.

1.250 x .010

5.

.900 x .010

3.

1.100 x .010

6.

.800 x .010

2.

1.000 x .010

1.

.900 x .010

Piston Depth 5.800 in./Piston Orifice .039 in.

Rear Arm Shock (p/n 1704-141)

Firecat Sno Pro

Compression:

Rebound:

10.

1.600 x .010

1.

1.420 x .015

9.

1.600 x .010

2.

1.420 x .015

8.

.900 x .008

3.

1.420 x .015

7.

1.600 x .010

4.

1.420 x .015

6.

1.600 x .010

5.

1.420 x .015

5.

1.600 x .010

6.

1.420 x .015

4.

1.420 x .010

7.

1.300 x .012

3.

1.300 x .010

8.

1.100 x .012

2.

.900 x .008

9.

.900 x .010

1.

1.560 x .950

10.

.800 x .010

Top out washer

11.

.620 x .920

Backup washer

Piston Depth 5.700 in./Piston Orifice .055 in.

9-142

Servicing I.F.P.

Style Shocks

„

NOTE: Some illustrations and photographs used

in the following sub-sections are used for clarity
purposes and are not designed to depict actual
conditions.

DISASSEMBLING

1. Remove the shock from the snowmobile.

2. Wash the shock body in parts cleaner; then dry

with compressed air to remove sand and dirt.

3. Place the shock into the Gas Shock Retaining

Blocks (p/n 0644-142); then remove shock eyelet
mounting axle and bushings from end cap.

„

NOTE: A paper shop towel between the shock

body and retaining blocks will help prevent scuff-
ing of the shock body.

AP110DA

4. Remove the screw from the bladder housing on the

bottom of the shock. Discharge all the pressure
from the shock using the Shock Inflation Needle
(p/n 0644-158). Open the valve in filler handle
until all pressure is released.

AG335

5. Using a 9/16-in. wrench, remove the brass bladder

housing from the lower end cap. Account for an
O-ring.

AP014

6. Using a large adjustable wrench (12-in. or 14-in.),

remove the end cap.

„

NOTE: 1994 and older shocks have Loctite on

the lower end cap. Heating the lower end cap may
be necessary. Use care not to overheat.

AP016DA

7. Using a 1-in. open end wrench, loosen the shock

shaft bearing cap a couple of turns.

! WARNING

Before servicing a gas shock absorber, first dis-
charge all pressure from the shock. Remove the
screw from the bottom of the shock 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.

! WARNING

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

! CAUTION

It is important that the Gas Shock Retaining
Blocks (p/n 0644-142) are used during both
disassembly and assembly. Any other method of
securing the shock body during these
procedures may deform the shock body cylinder.

9-143

9

„

NOTE: Do not remove the bearing cap at this

time.

AP026

8. Turn the shock so that the open end is up. Then

remove the Allen-head screw located in the center
of the floating piston. Account for a small O-ring.

AP022

9. Using a pair of pliers, pull the floating piston

assembly out of the shock body. Account for a pis-
ton ring and an O-ring.

10. Pour the oil out of the shock body.

11. Unscrew the shaft bearing cap and lift the shaft

assemble from the shock body.

AP027

12. Clean the inside of the shock body using clean

parts-cleaning solvent. Blow dry using com-
pressed air.

„

NOTE: Do not lay shock parts on a rag as it may

transfer lint to the parts causing internal shock
problems.

13. Remove the piston ring from the piston. Loosen

(but do not remove) the lock nut from the bottom
of the shock shaft; then clean the piston area with
clean parts-cleaning solvent to remove dirt or for-
eign material from between the valves. Dry the
piston and valves completely using compressed
air.

„

NOTE: If for some reason the piston must be

removed from the shock shaft, it must be installed
with its large seven slots located next to the lock
nut side of the shock shaft.

AP051

AP028

„

NOTE: If shock valving must be removed for

cleaning, remove all valving as a complete assem-
bly and place on a 5/16 x 3-in. cap screw to keep in
proper order. Note which side is the top side for
assembly purposes.

! WARNING

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

! WARNING

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

 

 

 

 

 

 

 

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