Polaris 600 RUSH 2010 Manual page 305

Walker Evans IFP Monotube Shock
™
Assembly
Shock Assembly
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.
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 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 body cap with the open end of the tube facing up
into the bench vise.
8. Install a new o-ring and wearband onto the IFP.
Lubricate the assembly with new shock oil.
9. Install the IFP into the shock with the flat side facing
the body cap.
10. Set the depth of the IFP using a Vernier Caliper.
Reference the IFP depth specification for the shock in
this chapter.
11. With the IFP set, verify the fill port bleed screw is
installed. Doing so will prevent the IFP from moving
when stroking the shock rod in later steps.
12. Slowly fill 3/4 of the shock body with new shock oil.
Walker Evans
2874522(Quart)
5W Shock Oil
™
13. Allow the oil to sit for several minutes to allow air
bubbles to escape. Gently tap on the shock body to
assist with removing any trapped air.
14. Carefully install the shock rod/bearing into the shock
body. Have a clean shop towel in hand to wipe up any
oil that spills out of the shock. Submerge the piston
valve assembly in the shock oil.
NOTE: From this point on, do not remove the piston
valve assembly from the shock oil.
15. Slowly and carefully stroke the shock rod up and down
to force the oil through the valve stacks and piston
orifices. Continue until air bubbles no longer rise to the
surface of the oil. Tap on the shock body/rod to assist
with the removal of any trapped air.
16. Completely fill the shock body with shock oil. Wrap the
bearing and open end of shock with a clean shop
towel.
17. Slide the bearing down the rod shaft. Install the
bearing into the shock body and securely tighten. Oil
must spill out during installation to ensure air does not
remain in the oil.
18. Remove the fill port bleed screw. Charge the shock
with nitrogen to 200 PSI using the gas fill tool, PN PS-
45259. The shock rod should be pushed outwards as
the IFP is compresses the shock oil.
19. Remove the fill tool from the fill port and reinstall the
bleed screw.
20. Test shock by pushing down on the shock rod. The rod
should extend slowly after pushing it into the tube with
no sound of trapped air inside the oil. If the sound of
air is present or the rate of shock rod compression or
extension dramatically changes, the shock should be
disassembled and the oil replaced.
Shocks
7
7.27