Fox™ Ifp Monotube Shock Assembly - Polaris 600 RUSH 2010 Manual

Shock Disassembly
CAUTION
SHOCK CONTENTS UNDER HIGH PRESSURE.
ALWAYS WEAR SAFETY GLASSES WHEN
WORKING WITH SHOCKS.
1. Remove the shock from the vehicle. Clean the shock
assembly to remove all dirt and foreign material.
Inspect the assembly for any noticeable signs of
damage.
2. Clamp the body cap end of the shock in a soft-jawed
bench vise.
3. Remove the bleed screw from the fill port. Insert the
needle of the gas fill tool, PN PS-45259, into the fill
port to depressurize the shock. Push the shock rod
down to ensure all nitrogen is expelled. Remove the
fill port from the body cap.
4. Remove the bearing assembly from the shock body.
Remove the bearing assembly/shock rod from the
shock body.
5. Release the bench vise and drain all of the oil out of
the shock body into a suitable container. Discard the
oil in accordance with local rules and regulations.
6. Position the bearing cap end of the shock over a clean
shop towel on the bench. Use compressed air applied
to the fill port bore to push the IFP out of the shock
body.
7. Using the shock body holding tool, PN 2871071,
clamp the shock body with the body cap pointed up in
a bench vise. Remove the body cap from the tube.
8. Remove the lock nut from the shock rod. Remove the
backup plate, rebound stack, piston, compression
stack, and top-out plates as one assembly. Orientate
these components on a clean shop towel as they are
assembled on the shock rod.
9. Remove the shock rod from the bearing.
10. With the shock disassembled, inspect all o-rings,
wiper, wearbands, and the ice scraper. It is
recommended that all be replaced with new parts.
11. Inspect the shock rod and shock body tube for
damage and/or pitting.
12. Inspect the rebound and compression stack valve
shims. Shims that are damaged, bent, chipped, or
wavy in appearance must be replaced.
13. Thoroughly clean all parts and dry with compressed
air.
FOX™ IFP Monotube Shock Assembly
Shock Assembly - IFP Air Bleed Shocks
CAUTION
SHOCK CONTENTS UNDER HIGH PRESSURE.
ALWAYS WEAR SAFETY GLASSES WHEN
WORKING WITH SHOCKS.
1. Place the shock rod eyelet in the bench vise. Apply a
liberal amount of shock oil to the surface of the shock
rod and internal bore of the bearing.
NOTE: Install jounce bumper if equipped.
2. Place the seal protector, PN 2201639, over the
threaded end of the shock rod. Carefully install the
bearing onto the shock rod.
3. Install the topout plate, and compression valve stack.
Use a Vernier Caliper and reference the valve stack
specifications in this chapter if unsure of the shim
order of assembly.
4. Install a new wearband on the piston valve. Lubricate
the piston with shock oil. Install the piston with the
greater number of relief ports facing up away from the
compression stack.
5. Install the rebound valve stack. Again, if unsure of
order of shims, use a Vernier Caliper and reference
the valve stack specifications for the shock in this
chapter.
6. Install the backup plate. Remove the seal protector
and install a new lock nut. Torque lock nut to 15-20 ft-
lbs (20-27 Nm).
7. Remove the shock rod from the bench vise. Secure
the shock body with shock body holding tool in the
vise.
8. Install the bearing/shock rod assembly into the body
tube. Tighten securely. Remove shock body from
vise. Secure shock rod eyelet in bench vise.
9. With the shock rod eyelet mounted in the vise, and the
body cap end of the shock pointed up, slowly fill 3/4
of the body tube with new shock oil.
FOX™ 5W Shock Oil
2870995(Quart)
10. Allow the oil to sit for several minutes to allow air
bubbles to escape. Gently tap on the shock body to
assist in removing any trapped air.
Shocks
7
7.23