Polaris RZR 800 2013, Manual

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5.54
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
FOX™ PODIUM ‘Piggyback’
Rebuild Information
When performing maintenance on FOX™ shocks, use
the Gas Shock Recharging Kit (PN 2200421), as it
contains the necessary valves, pressure gauge, and
fittings to deflate and pressurize shocks.
WARNING
FOX™ shocks contain high pressure nitrogen gas.
Extreme caution must be used while handling and
working with FOX™ shocks and related high pressure
service equipment. The pressure must be released
from the shock before disassembly. It is strongly
recommended you wear safety glasses and ear
protection during these procedures.
TIP: Extreme cleanliness is very important during all
disassembly and reassembly operations. This prevents
dirt or foreign particles from entering the shock, which
causes premature failure.
FOX™ PODIUM ‘Piggyback’ Special Tools
PART
NUMBER
DESCRIPTION
2200421
Gas Shock Recharging Kit
7052069-A
Gas Shock Recharging Needle
2871351 IFP Tool
PS-45281-A
Shock Body Holding Tool
(Front and Rear)
2872429
Shock Rod Holding Tool
PU-50939 Shock Seal Protector Sleeve
Bosch Automotive Service Solutions: 1-800-328-
6657 or http://polaris.service-solutions.com/
FOX™ PODIUM ‘Piggyback’ Disassembly
IMPORTANT: To prevent damage or marks to the
shock, the use of special tools and a soft jaw vise is
recommended.
WARNING
FOX™ shocks contain high pressure nitrogen gas.
Extreme caution must be used while handling and
working with FOX™ shocks and related high pressure
service equipment. The pressure must be released
from the shock before disassembly. It is strongly
recommended you wear safety glasses and ear
protection during these procedures.
1. Remove the shock from the vehicle and note the
spring preload distance (see Chapter 2 for factory
settings).
2. Thoroughly clean all shock components and shock
body prior to disassembly.
3. Back preload adjuster all the way down and carefully
remove spring retainer and spring.
4. Use the appropriate shock body holding tool (PS-
45281-A) to properly secure the shock body
assembly into a vice for service.
5. Remove the nylon ball from the reservoir cap using a
heavy duty pick. Discard nylon ball and replace with
new upon assembly.
6. Slowly loosen nylon ball retainer from reservoir cap
and allow nitrogen to completely escape.
7. Remove the nylon ball retainer.
BODY / STEERING / SUSPENSION