Polaris 340 LX 2007, Service Manual

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9.33
REAR SUSPENSION
9
the thread within the cylinder. Emulsion Shocks: Fill shock
body with 110cc's of oil. This will allow for the required
air space to properly gas charge the shock with nitrogen gas.
NOTE: After filling the shock body with oil, allow a
couple of minutes for all air bubbles to rise to the
top.
8. With the cylinder head assembly pushed down against the
piston, carefully, insert the piston rod and assembly into the
cylinder; Slightly oscillating the piston rod to allow piston
to enter shock body bore. A light coating of oil on the piston
wear band will ease installation.
9. Slowly push the piston rod and assembly into shock body
until the cylinder head assembly bottoms on the cylinder
counterbore. Slight up and down movement may be
required to allow all air to pass through piston assembly.
10. During installation, some shock oil will overflow. Wrap a
shop cloth around shock body to catch possible oil
overflow. Fast installation of the piston rod and assembly
may displace the floating piston from its original position.
This must not occur if the damper is expected to perform
as designed.
11. Using an open face spanner wrench tighten cylinder head
securely into the shock cylinder.
12. Pressurize the shock, through the pressure valve, with
nitrogen gas to the specified pressure.
13. If using RydeFX inflation tool Refer to Procedures for use
of replaceable inflation needle instruction manual found in
the RydeFX inflation tool case.
14. After being compressed, the piston rod should fully extend
from the shock body once the shock has been pressurized.
15. Install the small button head screw in the pressure valve
assembly and tighten securely.
16. Reinstall sleeve and bushings in lower shock mount.
Fox Monotube Disassembly
1. Remove the shock from the vehicle.
2. Remove the steel sleeve from the eyelet using the mallet
and an appropriate sized socket.
3. Pry the polyurethane bushings out using the flat blade
screwdriver, being careful not to scratch the body cap.
4. Clean the entire shock assembly with soapy water. Try to
remove as much dirt and grime as possible by scrubbing
with a soft bristle brush. Never pressure wash your shock,
as this can force water and debris inside which will damage
the seals. Dry the shock assembly with compressed air, if
available, or use clean towels.
5. Use a 3/32" Hex Key to remove the button head screw from
the FOX air valve in the shock body.
6. Securely clamp Fox Nitrogen Safety Needle in vice.
7. Insert the Fox Safety Needle squarely into center of gas
valve.
8. Using a blunt object, depress the air valve core to release
pressure.
9. When the shock is FULLY DISCHARGED, pull reservoir
away from the Fox Safety Needle in a straight, smooth
motion.
10. Clamp the body end eyelet of the shock securely in vice
with shaft side up.
11. Using the 1 3/8
"
wrench, loosen and unscrew the bearing
assembly from the shock body. If the body cap unscrews
instead of the bearing, that is OK. You will need to remove
both for this rebuild procedure.
12. Clamp the shock in the vice using the body clamp blocks.
If the bearing is still in the body, use the 1 3/8” end wrench
to loosen and unthread the bearing. If the body cap is what
needs removal, use the large crescent wrench to loosen and
unthread the body cap.
13. Remove the shaft assembly from the body tube, and place
on a clean, lint free paper towel. Remove the shock from
the vice and pour shock oil from body tube into a proper
disposal container. Do not re-use old shock oil.
14. Using the handle of the mallet, push the IFP out of the shock
body on to a folded shop towel.
15. Remove the bleed screw from the IFP using the 1/8" T-
Handle
16. Clean the IFP with solvent. Dry with compressed air in a
well ventilated area. If compressed air is not available, dry
parts using clean, lint free paper towels and let sit in a well
ventilated area to allow the solvents to evaporate.
17. Set body assembly aside on a clean, lint free towel.
18. Clamp the shaft eyelet securely in vice with the piston end
up.
19. Using a 9/16" wrench, remove the piston lock nut from the
end of the shaft.
20. Hold the tip of the Phillips Head Screwdriver against the
end of shaft. Hold the piston assembly under the top-out
plate and lift upwards. Slide the piston assembly onto the
shaft of the screwdriver. Pull the Screwdriver away from
shock shaft while supporting the piston assembly. Set this
on a clean, lint free towel. There are many pieces to the
piston assembly, and the assembly order of these pieces is
critical to the proper performance of your shock. This step
ensures that the proper order is kept.
21. Slide bearing assembly off of shaft. Use extreme caution
not to scratch inside of the bearing assembly when passing
it over the threads at end of shaft and set it on a clean, lint
free towel.
22. Remove the bleed screw from the IFP and set them both on
a clean, lint free towel.
Fox Monotube Assembly
1. Using a small pair of snap ring pliers, remove the snap ring
from the bearing housing. Using your fingers, remove the