Polaris Outlaw 500, Service Manual

Page: 146 / 202

5.37
BODY / STEERING / SUSPENSION
5
11. Clean the inside of the shock body using clean parts-
cleaning solvent and blow dry using compressed air.
12. Place the shock piston rod upper mount in bench vise, begin
piston and valve removal. Arrange parts removed in the
sequence of disassembly.
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 for chipping, cracking or being
missing.
Should any of these items be in question replacement is
recommended.
ASSEMBLY
1. Place the piston rod upper mount into the vise.
Reassemble damper rod assembly in the reverse order of
disassembly. Pay special attention to 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 to15-20 ft. lbs. (20-27 Nm) of torque.
2. Secure the shock body by its lower mount in vise. The use
of soft jaws is recommended to prevent damage or marks
to the shock.
Front Shock Part# 7043259
Rear Shock Part# 7043260
CAUTION
DO NOT OVER-TORQUE.
If excessive torque is applied, damage to the
piston and valves will occur.
CAUTION
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.