Arctic Cat Cougar Service Manual page 462

452
c. Remove the relief screw and 0-ring (51 and
52, Figure 20).
NOTE
Use the special removing/installing/set-
.. ting tool (part No. 0644-I69) or a long
bolt with I/4-20 thread to grip the piston
(50, Figure 20 ).
d. Pull the piston (50, Figure 20) from the
body.
e. Pour oil from the body, then clean the as-
sembly. Dry the cleaned parts with com-
pressed air.
NOTE
The shock absorber should be assembled
using new 0-rings. After parts are
cleaned, be careful that parts do not pick
up lint, such as from a rag, or any other
material before it is assembled. Very
small imperfections can result in leak-
age.
13. Assemble and bleed the cockpit adjuster as
follows:
a. Pour approved shock oil (part No. 0636-
664) or equivalent into the body until it
reaches the bottom of the threads.
b. Allow a few minutes for air bubbles to come
to the top and dissipate.
c. Lubricate the adjuster piston and rings ( 48-
50, Figure 20) lightly with shock oil and
insert the adjuster piston into the body.
NOTE
A special installing and setting tool (part
No. 0644-I69) is available for setting
the floating piston. The same tool will
grip the end of the floating piston to help
removal.
d. Position the adjuster piston at the distance
from the top of the body indicated in Table
2 (similar to measurement A, Figure 22).
Oil should be expelled from the hole in the
piston when installing.
CHAPTER SIXTEEN
NOTE
If
oil is not expelled when positioning the
piston in substep I3d, there is not
enough oil in the body. Add oil and make
sure that oil without bubbles flows from
the orifice in the piston. If necessary,
push the piston in, then pull the piston
up, but do not pull the piston above the
level of the oil.
e. Install the relief screw and 0-ring (51 and
52, Figure 20) in the adjuster piston.
f. Dump excess oil from the adjuster body. Oil
without air should be below the adjuster
piston and air should be above the piston.
g. Tum the adjuster knob (56, Figure 20)
counterclockwise all the way out.
h. Install the cap and adjuster assembly (53-
56, Figure 20). Tighten the cap securely.
NOTE
Make sure the adjuster knob has I/4-I/2
turn free play before contacting the pis-
ton. If free play is not correct, the posi-
tion of the piston may not be correct.
14. If detached, attach the hose and fittings to
the remote reservoir (23, Figure 20). The hose
( 40, Figure 20) to the cockpit adjuster should
remain removed until Step 19.
15. Begin filling the shock absorber with oil and
bleed air from the system as follows: Use only
approved shock oil (part No. 0636-664) or
equivalent.
a. Clamp the end cap ( 17, Figure 20) in a vise
with the shock body (15, Figure 20) up.
b. Hold the remote reservoir above the shock
body and add oil to the reservoir until oil
without bubbles flows into the shock body.
c. Lower the reservoir while filling the reser-
voir with oil. Oil should remain in the body
of the shock absorber and be near the top of
the reservoir.
d. Let the oil stand a few minutes to allow any
air bubbles to escape.