Owners Manual
Installation instructions Öhlins shock absorber kit
AC 202 for Arctic Cat, Firecat, ZR, Sabercat, rear
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Öhlins shock absorber type 36 PRCW
Adjusters
Your Öhlins shock absorber type 36 PRCW fea-
tures the following adjusters:
Compression damping
Adjustments are made on top of the reservoir.
Rebound damping
Adjuster screw on the piston shaft in the end
bracket. An ordinary coin may suffice as a tool.
When delivered, the Öhlins shock absorber is
dialed to recommended settings for the specific
brand and make of the snowmobile. If you have
changed the setting, check like this:
The adjusters have a normal right hand thread.
Turn clockwise to fully closed. Turn counter clock-
wise to open and count the clicks until you reach
the recommended number of clicks.
Do not use to much force, delicate sealing sur-
faces can be damaged.
Rebound adjuster
Compression
adjuster
Setup data
Lenght 369 mm
Stroke 124 mm
Preload on rear suspension springs; see page 5.
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00. Fax +46 8 590 025 80.
www.ohlins.com
AC 202, issued 04 05 07
Before installation
Öhlins Racing AB can not be held responsible for
any damage whatsoever to shock absorber or
vehicle, or injury to persons, if the instructions for
fitting and maintenance are not followed exactly.
Similarly, the warranty will become null and void
if the instructions are not adhered to.
WARNING!
1. Installing a shock absorber, that is not
approved by the vehicle manufacturer, may
affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage whatsoever
that may occur after fitting the shock
absorber. Contact an Öhlins dealer or other
qualified person for advice.
2. Please study and make certain that you
fully understand all the mounting instructions
and the owners manuals before handling this
shock absorber kit. If you have any questions
regarding proper installation procedures,
contact an Öhlins dealer or other qualified
person.
3. The vehicle service manual must be
referred to when installing the Öhlins shock
absorber
Safety signals
Important information concerning safety is
distinguished in this manual by the
following notations:
The Safety alert symbol means:
Caution! Your safety is involved.
WARNING!
Failure to follow warning instructions
could result in severe or fatal injury
to anyone working with, inspecting or
using the suspension, or to bystanders.
CAUTION!
Caution indicates that special pre-
cautions must be taken to avoid dam-
age to the suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
Öhlins products are subject to continual improve-
ment and development. Consequently, although
these instructions include the most up-to-date
information available at the time of printing, there
may be minor differences between your suspen-
sion and this manual. Please consult your Öhlins
dealer if you have any questions with regard to
the contents of the manual.
NOTE!
During storage and transportation, espe-
cially at high ambient temperature, the oil
and grease used for assembling may run out
inside the packing and damage the
expanded polystyrene packing material. This
is not unusual and is in no way detrimental
to the shock absorber.
Kit contents
Before installing the shock absorber, please
check the contents of the kit, listed on the front
page of this instruction. If anything is missing,
contact your Öhlins dealer.
Description Pcs. Part No.
Shock absorber 36PRCW 1 AC 202
Sticker Öhlins 2 00192-01
Sticker memo notes 1 01180-01
Owners manual 1
Notes
WARNING!
1. It´s advisable to have an Öhlins dealer or other
qualified person to fit your shock absorber.
2. Instructions in the vehicle service manual are
to be followed when changing the shock
absorber.
3. When working on a lifted vehicle it must be
securely supported to prevent it from falling.
Mounting Instructions
1
Lift the rear end of the snowmobile so the rear sus-
pension has ground clearance. Make sure it is
steadily positioned and will not fall down.
40 mm
Right
Left
22 mm
CAUTION!
For certain snowmobiles it is not advisible to roll
it over or lay it on it´s side. Especially for ma-
chines with injection oil system, loss of lubrica-
tion due to air in the system can damage the en-
gine. Also fuel can leak from the gasoline tank.
NOTE!
When disassembling suspension components it´s
always easier first to loosen, but not remove all
bolts, before removing the components. Re-
versed order when assembling, tightening all
bolts is the last thing you should do.
2
Release the spring preload of the rear suspen-
sion springs by loosening the nut on the right side.
Hold the spring in a firm grip and pull the shaft out
approxiomately 40 mm. Remove the spring
bracket. Release the spring carefully. It is advis-
able to have a second person assisting.
WARNING!
The springs are very heavily preloaded. It is of great-
est importance to hold the spring in a firm grip when
it´s attachment is beeing removed. There is risk for
damages from squeesing. Use protection gloves.
4
Remove the rear suspensions four attachment
bolts. To loosen the rear bolts it might be neces-
sary to use a 22 mm open-end wrench to hold the
inside nut.
3
When releasing the spring on the left side the two
front idler wheels inside the skid will be released.
When the shaft is removed out on the left side of
the snowmobile, a replacement (i.e. a screwdriver)
must be inserted from the right, to prevent the
wheels from moving away.
Reinsert the shaft when the left spring has been
released. Hold the spring in a firm grip and re-
lease the spring carefully.
2
4
3
Notes
5
5
Loosen the track straining wheels as much as
possible.
6
Press the rear suspension unit together, hoist the
rear end of the snowmobile high enough so it
can be pulled out from the track.
7
If the rear inner idler wheels have a common axle,
the axle will collide with the external reservoir on
the shock absorber (a). In this case you will have
to change to brackets and wheels for individual
attachment to each slide (b). Please contact your
Arctic Cat dealer for the correct parts.
Pull rod
Rear shock absorber
8
9
7
9
Remove the idler wheel on the left hand side of
the shock absorber front bracket. Loosen and
remove the nut and shaft.
10
Loosen and remove the shock absorber from the
front bracket. The two pull rods will hang loose.
11
Fit the Öhlins shock absorber in reverse order.
Start with reassembling the front bracket together
with pull rods and idler wheels.
8
Loosen the rear shock absorber bracket on the
link rear arm and remove the bolt and shock ab-
sorber end eye.
7
12
Put the suspension unit back inside the track.
11
a
b
Rebound adjuster
upwards
NOTE!
The reservoir is directed forwards, downwards
and rebound adjuster rearwards facing up.
Equal distance
Spring pre-load
is adjusted by
turning the
spring seat.
NOTE!
The spring preload affects the ride height, it does
not affect bottoming.
It might be necessary to increase the rebound
damping somewhat when using more spring
preload than the delivered setting.
If you experience the suspension bottoming out
too often, do not increase spring preload. It will
not fix your problem, and your ride height might
make your coupling adjuster run out of the range
described above, thus creating a harsh ride. In-
stead, change to a stiffer spring and again ad-
just your spring preload as described above.
If you experience that the suspension is too
stiff, do not decrease spring preload. It will not
fix your problem, and your ride height might
make your coupling adjuster run out of the range
described above, thus creating a harsh ride. In-
stead, change to a softer spring and again ad-
just your spring preload as described above.
13
Fit the unit to the chassis by the four attachment
bolts. Preload the spring and fix them in position.
Set the track deflection according to the Artic Cat
Owners manual.
NOTE!
Make sure that all bolts are tightened to the cor-
rect torque and that nothing fouls or restricts the
movement of the shock absorber when the sus-
pension is being fully compressed or extended.
14
Continue your work according to the Öhlins Owners
Manual, section Adjustments.
Of course, if you carry heavy luggage, or a pas-
senger on a 2-seater, you will need to do this
adjustment with these in place.
Rear ride height and suspension comfort
It is very important that the rear ride height is
adjusted correctly. Due to the coupling device in
the rear suspension, the rear ride height and com-
fort are linked together. If the ride height is not
within the right range, the center and rear shock
absorbers may start working parallel in unwanted
situations, thus creating a too stiff suspension
and a harsh ride.
NOTE!
It is of importance that this adjustment is carried out
on a flat surface and the most correct setting is made
indoors when the snowmobile is thawed out/ warmed
Recommended rear ride height
When you sit on the snowmobile in riding posi-
tion, wearing all your riding gear, we recommend
the coupling adjuster free play to be equal in both
directions, assuming that the coupling adjuster
is in its standard setting.
Increase or decrease the spring preload until you
have reached the middle position of the coupling
adjuster.
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