Polaris RZR 800 2013, Manual

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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
17. Pull IFP up until its top is approximately 1" (2.54 cm)
from top of reservoir and remove the IFP Tool. Using
a 3/32" Allen wrench, install the IFP bleed screw.
IMPORTANT: When the IFP Tool is removed, the
IFP must remain submerged in shock oil to
prevent air from getting under the floating piston.
18. Fill the shock body with oil approximately 1/4" below
the threads.
19. Apply a thin film of oil to the wear band on the
damping piston. Slowly insert the shock rod
assembly into the body until the damping piston
assembly is approximately 1" below the oil surface.
• Move rod up and down slowly over a range of
about 1" until no air bubbles rise from damping
piston. Be careful to keep damping piston at least
1/4" below the surface of the oil during this
process.
• While holding the shock rod, apply 2 - 3 sharp
blows to the rod eyelet with a rubber mallet driving
the piston down into the shock body. This opens
the valves on the damping piston. You will see the
released air bubbles come to the surface of the oil.
20. Add oil to the body tube until the surface of the oil is
at the top of the shock body threads.
NOTE: During installation, some shock oil will
over flow. Wrap a shop cloth around the shock
body to catch any oil overflow.
21. Pull the damping piston up until it is just below the
surface of the oil.
22. Hold the rod eyelet with one hand. With other hand,
slide the bearing cap down the shaft until contact
with the body is made. Oil will overflow from around
the bearing cap.
23. Screw the bearing cap assembly into the shock body
by hand, holding the rod up so that the bearing cap is
in contact with the bottom of the damping piston
assembly. Be careful not to cross-thread the bearing
assembly.
24. Using a 1" open-end wrench, tighten the bearing
cap.
25. Using a 3/32" Allen wrench, remove the IFP bleed
screw.
BODY / STEERING / SUSPENSION