Polaris RZR 800 2013, Manual

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5.60
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
16. Install the IFP into the reservoir. Keep top of
reservoir covered with a clean shop towel.
17. Press IFP downward until 1/4" (6.35 mm) of shock oil
is on top of the IFP.
18. Install a new O-ring on the IFP center screw and
install the screw. Tighten the screw sufficiently.
19. Install the IFP tool and fully depress IFP into the
reservoir bore until bottomed. Measure IFP height for
later reference.
20. Fill the main shock body with shock oil until it is 2"
(50.8 mm) from the top of the shock body.
21. Pass a small heating torch over the shock body to
remove any air bubbles from the oil.
22. Insert the shock rod / piston assembly into shock
body. Be sure the piston band stays in the proper
position. Do not install bearing assembly at this time.
23. Press shaft downward. Rotate and wiggle the shaft
as it submerges in the shock oil until no more air
bubbles rise out of the shock oil.
24. Hold pressure downward on IFP tool. Stroke shock
rod assembly up and down 1/4" (6.35 mm) to work
the air bubbles out of the piston and piston ports.
25. Slide the bearing assembly partially into the shock
body.
26. Tap shock rod eyelet with a rubber mallet 3-5 times
to remove any trapped air from the valve shims.
27. Slide bearing assembly up and pass a small heating
torch over the shock body to remove any air bubbles
from the oil.
28. Add shock oil to 1/8" (3.18 mm) below the top of the
shock body.
29. Wrap a clean shop towel around top of shock body
and depress the bearing assembly downward below
the retaining ring groove.
30. Install the bearing assembly retaining ring and clean
excess shock oil. Properly dispose of shop towel.
31. Add shock oil to reservoir until it is 1" (25.4 mm)
above the top of the IFP.
32. Remove the IFP center screw and O-ring.
33. Pull upward on shock shaft until fully extended and
seated against the bearing assembly retaining ring.
BODY / STEERING / SUSPENSION