Arctic Cat Cougar Service Manual page 459

TRACK AND REAR SUSPENSION
b. Heat the eyelet (26, Figure 19) to soften the
Loctite, then unscrew the eyelet.
c. Pull the end cap (23, Figure 19) and seal
from the rod.
WARNING
Do not damage the end cap by scratch-
ing or gouging while removing or in-
stalling the rod seal. Do not lay parts on
a rag or other suiface where they can
pick up lint that would cause leakage.
Very small impeifections can result in
leakage.
d. Remove the plastic wiper, rubber wiper and
0-ring (22, Figure 19) from the removed
end cap.
e. Clean the cap and rod thoroughly. Inspect
both for cracks, scratches, gouges or any
other damage.
f. Install the 0-ring, rubber wiper and plastic
wiper in the cap, then coat the installed seal
with oil.
g. Slide the cap with the installed seal over the
end of the rod. Be very careful not to dam-
age the seal while installing.
h. Apply Loctite 271 on the threads of the rod,
then install the eyelet. Tighten the eyelet
securely.
11. Replace the piston ring (24, Figure 19).
12. Disassemble the reservoir as follows:
a. Press the end cap (31, Figure 19) in until it
is about 25 mm ( 1 in.) from the end of the
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449
reservoir body, then remove the snap ring
(32, Figure 19).
b. Clean the end of the reservoir and end cap
thoroughly.
c. Grip the end cap (31, Figure 19) with pliers,
then pull the end cap slowly from the reser-
voir.
d. Thread a 1/4 in. coarse-thread bolt into the
end of piston (35, Figure 19), then grip the
bolt with pliers and pull the piston from the
reservOir.
e. Pour oil from the reservoir and shock body,
then clean the assembly. Dry the cleaned
parts with compressed air.
13. Clamp the cap (1, Figure 19) of the shock
body in a soft-jawed vise with the body upright.
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.
14. Hold the reservoir lower than the shock
body and fill the reservoir with approved shock
oil (part No. 0636-664) or equivalent.
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. Make sure the valve ( 43, Fig-
ure 19) is removed while installing the
floating piston in Step 15.
15. Coat the rings on the floating piston (35,
Figure 19) with oil and insert the piston into the
reservoir until it is located at the correct distance
from the end (A, Figure 22). Refer to Table 2
for the correct distance to position the floating
piston.
16. Remove the bolt from the floating piston.
Make sure the piston is still the correct distance
from the end of the reservoir.