Arctic Cat Cougar Service Manual page 431

FRONT SUSPENSION AND STEERING
g. Apply Loctite 271 on the threads of the rod,
then install the eyelet. Tighten the eyelet
securely.
14. Replace the piston ring (12, Figure 24).
15. Use the proper size Allen wrench andre-
move the small screw and 0-ring (23 and 24,
Figure 24).
16. Grip the piston (20, Figure 24) with pliers,
then pull the floating piston from the body.
17. Clean the shock body thoroughly, then blow
dry with compressed air.
18. Clamp the housing (19, Figure 24) in the
special holding fixture (part No. 0644-158) or
equivalent.
19. Lubricate the piston ring and cap 0-ring (4
and 12, Figure 24).
20. Compress the piston ring with your fingers
and slowly move the piston into the shock body
until the cap can be installed.
21. Install the cap (3, Figure 24) and tighten into
position.
22. Reposition the shock housing with the open
end upright.
23. Pull the rod out to its fully extended posi-
tion. Fill the body with approved shock oil (part
No.' 0636-664) or equivalent until the oil is 1.5
in. from the top (Figure 26).
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NOTE
After filling the shock absorber with oil,
it may be necessary to wait as long as
five minutes to allow the air to rise. Do
not shake or otherwise agitate the shock
oil before or during filling. The installed
fluid must be free of air bubbles before
continuing.
421
24. Move the shock rod slowly up and down a
few times to remove any air trapped around the
piston. Keep the piston below the level of the oil.
25. Check the oil level and make sure the oil
level is still 1.5 in. from the top of the body.
26. Lubricate the floating piston and rings (20,
21 and 22, Figure 24) lightly with shock oil and
insert the floating piston into the body.
NOTE
A special installing and setting tool (part
No. 0644-169) is available for setting
the floating piston. The same tool will
grip the end of the floating piston to help
removal.
27. Position the floating piston at the distance
from the top of the body indicated in Table 2
(Figure 27). Oil should be expelled from the
hole in the piston.
NOTE
If
oil is not expelled when positioning the
floating piston in Step 27, there is not
enough oil in the reservoir. Add oil and
make sure that oil without bubbles flows
from the orifice in the floating piston. If
necessary, push the piston in, then pull
the piston up, but do not pull the piston
above the level of the oil.
28. Install the Allen head screw and 0-ring in
the floating piston. Hold the piston with a 9116
in. wrench while tightening the Allen head screw.
29. Dump excess oil from the shock body.
30. Apply a light coat of Loctite 291 to the
threads of the end cap. Install the cap on the
shock body. Hold the body of the shock with
special blocks (part No. 0644-142) and tighten
the end cap securely.