Arctic Cat Cougar Service Manual page 460

1990-1998
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450
17. Install a new 0-ring ( 41, Figure 19) on the
end cap, lubricate the 0-ring, then install the cap.
18. Press the cap into the reservoir about 25 mm
(1
in.). Do not move the floating piston.
19. Install the retaining snap ring (32, Figure
19), then pull the end cap back against the snap
ring.
20. Fill the body with approved shock oil (part
No. 0636-664) or equivalent until the oil is 1/4
in. (B, Figure 22) from the top of the body. Wait
about five minutes for the bubbles to rise after
filling. There should not be any air mixed with
the oil.
21. Slide the cap (23, Figure 19) on the rod until
it is about 1/8-114 in. from the piston and valve
assembly.
NOTE
After assembling the piston and bearing
cap in Step 22 and 23, do not move the
piston in the body until assembly is com-
plete and the reservoir has been pressur-
ized.
22. Compress the piston ring with your fingers
and slowly slide the piston into the shock body
until the bearing cap can just be installed. Do not
move the piston into the body further than nec-
essary.
23. Install the cap (23, Figure 19) using a new
0-ring (24, Figure 19) and tighten into position.
24. Install the valve ( 43, Figure 19) using a new
0-ring ( 42, Figure 19).
25. Grip the protrusion in the center of the end
cap ( 40, Figure 19) with locking needlenose
pliers, then clamp the pliers in a vise. This pro-
cedure will allow the filling valve to be pressed
against the valve while filling.
NOTE
Fill the system with nitrogen gas. Do not
attempt to fill the shock with air.
26. Insert the inflation needle (part No. 0644-
158) or equivalent into the valve, open the fill
valve, then slowly increase the regulated pres-
sure to 200 psi.
CHAPTER SIXTEEN
27. When filled, close the filler valve, remove
the inflation needle and reduce the regulated
pressure to zero. Install and tighten the screw
(39, Figure 19).
28. Test operation of the assembled shock as
follows:
a. Compress the shock fully.
b. If spongy spots are felt while compressing,
it indicates air in the oil. Disassemble and
fill with oil that does not contain any air
bubbles.
c. When released, the shock absorber rod
should extend fully. Failure to extend indi-
cates binding or pressure leakage.
d. Submerge the shock in water to check for
nitrogen leaks.
Units with cockpit control
Refer to Figure 20 for this procedure.
1. Remove the screw and washer (31, Figure
20).
2. Release the pressurized nitrogen carefully us-
ing the special tool (part No. 0644-158) or
equivalent.
3. If not already done, separate the coupler (41
and 42, Figure 20), then release pressure in the
hose.
4. Disassemble the reservoir as follows:
a. Clamp the remote reservoir body (23, Fig-
ure 20) in a special holding fixture (part No.
0644-158) or equivalent.
b. Press the end cap (27, Figure 20) in until it
is about 25 rnrn ( 1 in.) from the end of the
reservoir body, then remove the snap ring
(20, Figure 20).
c. Clean the end of the reservoir and end cap
thoroughly.
d. Grip the end cap (27, Figure
18)
with pliers,
then pull the end cap slowly from the reser-
voir.
e. Remove relief screw and 0-ring (32 and 33,
Figure 20).

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