Polaris Ranger RZR 800 Manual page 221

13. Pull the IFP up until its top is approximately 1" (2.54 cm)
from the top of the 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.
14. Fill the shock body with oil approximately 1/4" below the
threads.
15. 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 the rod up and down slowly over a range of about
1" until no air bubbles rise from the damping piston. Be
careful to keep the 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.
16. Add oil to the body tube until the surface of the oil is at the
top of the shock body threads.
BODY / STEERING / SUSPENSION
NOTE: During installation, some shock oil will over
flow. Wrap a shop cloth around the shock body to
catch any oil overflow.
17. Pull the damping piston up until it is just below the surface
of the oil.
18. 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.
19. 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.
20. Using a 1" open-end wrench, tighten the bearing cap.
21. Using a 3/32" Allen wrench, remove the IFP bleed screw.
22. Set the IFP depth to the specified length from the top of the
reservoir.
IFP Depth:
3.00" (76.2 mm)
23. Using a long 3/32" Allen wrench, install the IFP bleed
screw.
NOTE: Apply grease to the end of the Allen wrench
so the bleed screw sticks to it during installation.
24. Pour the residual shock oil out of the reservoir into a proper
disposal container.
= In. / mm.
5.61
5