Polaris Outlaw 500 Service Manual page 147

BODY / STEERING / SUSPENSION
3. Thread the positioning head onto the I.F.P locator tool and
adjust the top of the value indicator to the appropriate
measurement.
NOTE: Depending on which shock absorber is being
worked on, adjust the piston location tool to the
specified depth indicated in the shock specification
chart, located on the bottom of Page 5.34.
4. Apply a thin film of oil onto the floating wear band and O-
ring and install the floating piston into the top of the shock
body, positioning it below the counterbore.
5. Using the tool as a handle, push the floating piston down
into the shock body, being careful not to damage I.F.P wear
band and O-ring, until the value indicator knob comes in
contact with the shock body. The piston should now be
located correctly.
6. Apply a light film of grease to the pressure valve port
counterbore through 360º, where the pressure valve
assembly O-ring meets.
5.38
7. Screw the pressure valve assembly into the valve port by
hand with a slotted head screwdriver. Tighten to 100-110
in. lbs. (11-12 Nm) of torque.
8. Fill the shock body with shock oil to the bottom of the
threads within the cylinder.
NOTE: After filling the shock body with oil, allow a
couple of minutes for all air bubbles to rise to the
top.
Polaris Gas Shock Oil - P/N 2870995
9. With the cylinder head assembly pushed down against the
piston, carefully, insert the piston rod and assembly into the
cylinder; Slightly oscillating the piston rod to allow piston
to enter shock body bore. A light coating of oil on the piston
wear band will ease installation.
10. Slowly push the piston rod and assembly into shock body
until the cylinder head assembly bottoms on the cylinder
counterbore. Slight up and down movement may be
required to allow all air to pass through piston assembly.
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