Polaris FST IQ 2007, Service Manual

Page: 272 / 325

9.27
Shocks
9
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
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 PS-5 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.
CAUTION
Point air valve away from face and body when charging
or discharging any shock.