Polaris 2003 Pro X Service Manual page 260

REAR SUSPENSION/TRACK/TRACTION
Place the shock piston rod upper mount in bench vise,
begin piston and valve removal. Arrange parts re-
moved in the sequence of disassembly. The piston
should have the flat slots facing the nut end (as high-
lighted in black). (PICTURE 9)
Items to inspect: Piston rod for straightness, nicks or
burrs. Cylinder Head Assembly / DU Bearing clean, in-
spect, 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 (ski shocks only) for
chipping, cracking or being missing.
Should any of these items be in question replace-
ment is recommended.
ASSEMBLY:
Place the piston rod upper mount into the vise. Re-
assemble damper rod assembly in the reverse or-
der 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. (PICTURE 10)
CAUTION: DO NOT OVER--TORQUE. If exces-
sive torque is applied, damage to the piston and
valves will occur.
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. (PICTURE 11)
CAUTION: It is important that the gas shock be re-
tained 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: Points 3 through to 5 are not applicable for
emulsion shocks (P/N: 7041992) Proceed to point
#15
Thread the positioning head onto the I.F.P locator
tool and adjust the top of the value indicator to the
appropriate measurement. (PICTURE 12)
NOTE: Depending on which shock absorber is be-
ing worked on, adjust the piston location tool to the
specified depth indicated in the shock specification
charts.
7.22
Flats
Shims
Nut
Shaft
10
11
12