2004 Ski-Doo Racing Handbook, Page 42Get this manual
SECTION 03CHASSIS PREPARATION
A06F18B
1Schrader valve 1.5-2 Nm (13-17 lbfin) 2Schrader cap 5-6.5 Nm (44-57 lbfin)
Adding Gas Pressure Nitrogen (N2) can now be added to damper bodyNOTE: Never substitute another gas for nitrogenNitrogen has been selected for its inert qualities and will not contaminate the gas chamber of the shockPreset your pressure regulator to 2070 kPa (300 PSI) nitrogen (N2), this gas pressure will restore the correct pressure for your damperCAUTION: Do not exceed the recommended pressure valuesWhen removing and retightening the Schrader valve acorn nut use minimal torqueWhen the cap is over tightened and subsequently removed it may prematurely break the seal of the Schrader valve to the shock body and cause loss of nitrogen charge without being noticedIf you suspect this has happened then recharge the shock as precautionInspect the acorn cap before installation to ensure that the internal rubber gasket is in its proper position
Damper gas pressure cannot be confirmed by using pressure gaugeThe volume of gas in the shock is very small, and the amount lost during gauge installation will lower the pressure too much and require refillingAfter recharging is complete and before installing the spring the rebuilt shock should be bench-testedStroke the shock to ensure full travel and smooth compression and rebound actionIf the shaft moves in or out erratically this could indicate too much air is trapped insideIf the shaft will not move or has partial travel then it may be hydraulically lockedIn either event the shock must be rebuilt againPay particular attention to the placement of the IFP, quantity of oil and shim stackpiston assembly2