Polaris 340 LX 2007, Service Manual

Page: 246 / 327

9.32
REAR SUSPENSION
the gauge will deplete the pressure in the shock and
will affect performance.
14. Check for any leaks.
15. Protect the shock rod (2) and carefully place it back onto
vehicle.
Ryde Fx Mono-tube Shock Disassembly
Procedures for the proper disassembly and assembly of RydeFX
gas charged IFP and emulsion mono-tube shock absorbers.
1. Remove the shock(s) from the vehicle.
2. Before unscrewing pre-load springs, measure the
compressed length of the installed spring and mark position
for reinstallation.
3. If the shock incorporates a spring, remove the spring and
all collateral retainers.
4. Wash the shock body in parts cleaner; then dry with
compressed air to remove sand and dirt.
5. Remove bearing, sleeve and/or bushings from lower shock
mount eyelet. Secure the lower mount of the shock in a vise.
The use of soft jaws is recommend to prevent damage or
marks to the shock.
6. Remove the small button head screw from the pressure
valve assembly.
7. Depressurize the shock.
8. Internal Floating Piston Shocks, using a slotted
screwdriver, loosen the pressure valve assembly counter-
clockwise two full revolutions allowing the gas pressure to
fully escape past the pressure valve assembly O-ring.
9. Emulsion Shocks: With the shock inverted and the piston
rod fully extended, secure the lower mount of the shock in
a vise. Allow a couple of minutes for the gas pressure to
separate from the oil and rise to the top. Using a rag as a
shield to prevent spraying gas and oil; place rag over top
the pressure valve assembly and slowly loosen the valve
assembly with slotted screw driver three full revolutions,
allowing all the gas pressure to escape past the pressure
valve assembly O-ring.
10. Allow all the gas pressure to escape before proceeding with
the removal of the pressure valve assembly. Pressurized gas
and shock oil could eject the valve assembly from the
cylinder resulting in bodily injury.
11. Using a slotted screwdriver, remove the pressure valve
assembly from the lower end mount. Account for an O-ring.
12. Using an adjustable face spanner (PN PS45262), fully
loosen and remove cylinder head assembly.
13. Pour the oil out of the shock body. Discard old oil into an
approved storage container and dispose appropriately.
Never reuse damper oil during shock rebuild.
14. Using the I.F.P extraction tool thread the tool into the I.F.P
and pull upwards, removing the I.F.P from the shock body.
Account for wear band and an O-ring. Note: Not applicable
for emulsion shock
15. Clean the inside of the shock body using clean parts-
cleaning solvent and blow dry using compressed air.
16. Place the shock piston rod upper mount in bench vise, begin
piston and valve removal. Arrange parts removed in the
sequence of disassembly. The piston should have the flat
slots facing the nut end (as highlighted in black).
17. Items to inspect: Piston rod for straightness, nicks or burrs.
Cylinder Head Assembly / DU Bearing clean, inspect, or
replace. Inside of shock body for scratches, burrs or
excessive wear. Teflon piston and I.F.P wear band for cuts,
chipped or nicked edges, or excessive wear. O-rings for
nicks, cuts, or cracks. Cap and rod seals for nicks, cuts or
cracks. Valve discs for kinks or waves. Compression
bumpers (ski shocks only) for chipping, cracking or
missing. Should any of these items be in question
replacement is recommended.
Ryde Fx Mono-tube Shock Assembly
1. Place the piston rod upper mount into the vise. Reassemble
damper rod assembly in the reverse order of disassembly.
Special attention should be paid the order of the Rebound
and Compression disc (shim) stacks, ensuring that they are
in the same order prior to disassembly. Tighten the lock
nut to 15-20 ft-lb. of torque. DO NOT OVER-TORQUE.
If excessive torque is applied, damage to the piston and
valves will occur.
2. Secure the shock body by its lower mount in vise. The use
of soft jaws is recommend to prevent damage or marks to
the shock. It is important that the gas shock be retained in
the vice by the lower mount. Any other method of securing
the shock body during these procedures may deform the
shock body cylinder.
NOTE: The next points on IFP are not applicable for
emulsion shocks. Proceed to assembly of the
pressure valve.
3. Thread the positioning head onto the I.F.P locator tool and
adjust the top of the value indicator to the appropriate
measurement. Depending on which shock absorber is being
worked on, adjust the piston location tool to the specified
depth indicated in the shock specification chart.
4. Apply a thin film of oil onto the floating wear band and O-
ring and install the floating piston into the top of the shock
body, positioning it below the counterbore.
5. Using the tool as a handle, push the floating piston down
into the shock body, being careful not to damage I.F.P wear
band and O-ring, until the value indicator knob comes in
contact with the shock body. The piston should now be
located correctly.
6. Screw the pressure valve assembly into the valve port by
hand with a slotted head screwdriver; and tighten to 100-
110 in.lb of torque.
7. Fill the shock body with shock oil. Internal Floating Piston
Shocks: Fill the shock body with shock oil to the bottom of