162
Suspension
The following suspension system components should be
inspected periodically to ensure proper operation.
A. Shock absorber rods bent, pitted, or damaged.
B. Reservoirs damp or leaking.
C. Shock absorber body damaged, punctured, or leaking.
D. Shock absorber eyelets broken, bent, or cracked.
E. Shock absorber eyelet bushings worn, deteriorated,
cracked, or missing.
F. Shock absorber spring broken or sagging.
G. Sway bar mountings tight and bushings secure.
H. Proper pre-load and damping for conditions.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropri-
ate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Shock Absorbers
NOTE: For Limited models, proceed to Shock
Absorbers (Limited) in this section.
REMOVING
1. Secure the vehicle on a support stand to elevate the wheels
and to release load on the suspension.
2. Remove the two cap screws and nuts securing each front
shock absorber to the frame and lower A-arm. Account for
bushings and sleeves from each.
3. Remove the two cap screws and nuts securing each rear
shock absorber to the frame and lower trailing arm.
Account for bushings and sleeves from each.
CLEANING AND INSPECTING
1. Completely remove pre-load by turning the adjusters to
the end of the threads and removing the retainer; then
remove the spring.
WC618A
2. Clean all shock absorber components in parts-cleaning
solvent.
3. Inspect each shock rod for nicks, pits, rust, bends, and oily
residue.
4. Inspect all springs, spring retainers, shock rods, sleeves,
bushings, shock bodies, and eyelets for cracks, leaks, and
bends.
INSTALLING
1. Place the shock absorber spring over the shock absorber,
compress the spring, and install the retainer.
2. Place bushings and sleeves (where appropriate) into shock
eyelet; then install shocks with two cap screws and nuts.
3. Tighten the front shock absorber cap screws to 40 ft-lb
(head side). Tighten the upper rear shock absorber cap
screws to 40 ft-lb and the lower rear shock absorber cap
screws to 35 ft-lb.
4. Remove the vehicle from the support stand.
REBUILDING
Inspection
Inspect all components for any signs of wear or damage
and replace parts as necessary.
Preliminary Set-Up
1. Clean and dry the shock before beginning disassem-
bly.
2. Note spring preload before removing the spring. Stroke
the shock to assess its condition and function. Compress
and rebound adjustment positions should be noted.
NOTE: This is done by turning the adjustment
knobs clockwise while counting the number of clicks
until the adjustment knob is fully closed or bottomed.
There are six clicks per full 360° revolution of the
adjustment knob. After noting positions, open all
adjustment knobs by turning them counter-clockwise
fully open.
Description
p/n
Shaft Bullet Tool
0644-404
Inflation Needle
0744-020
Piston Location (IFP) Tool
0644-575
Gas Shock Rod/Body Clamping Tool
0644-425
