Polaris 600 RUSH 2010 Manual page 302

Shocks
11. After a few minutes, slowly and carefully pump the
shock body up and down to force the oil through the
valves stacks and piston orifices. Continue until air
bubbles no longer rise to the surface of the oil.
12. After removing all of the air from the shock oil, collapse
the shock rod into the shock body.
13. Remove the bleed screw from the IFP. Install a new
o-ring and wearband onto the IFP. Lubricate the
assembly with shock oil.
14. Set the depth of the IFP locator tool, PN 2871351, with
a Vernier Caliper. The IFP depth specifications are
noted for all rebuildable shocks in this chapter.
15. Slowly push the IFP down into the shock body until the
IFP locator tool bottoms-out on the tube. Tap on the
shock body to remove any air trapped under the IFP.
NOTE: The IFP must be completely submerged in
shock oil to ensure air does not become trapped
under the IFP.
16. With the IFP correctly set inside the tube, install the
IFP bleed screw. Make sure not to move the shock rod
after installing the screw as doing so will move the IFP.
17. Remove the shock from the bench vise and pour out
the remaining shock oil into a suitable container.
18. Install the body cap onto the shock body. Tighten
securely.
19. Reinstall the fill port. Charge the shock with nitrogen
to the specified pressure using the gas fill tool, PN PS-
45259. The shock rod should be pushed outwards as
the IFP compresses the shock oil.
20. Remove the fill tool from the fill port and reinstall the
bleed screw.
21. 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.
7.24
FOX™ IFP Monotube Shock Assembly
Shock Assembly - Bearing 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. With the body cap removed from the shock body, the
IFP must be installed as shown in the illustration.
Install a new o-ring and wearband onto the IFP.
Lubricate the assembly with shock oil.
9. Set the depth of the IFP locator tool, PN 2871351, with
a Vernier Caliper. The IFP depth specifications are
noted for all rebuildable shocks in this chapter.
10. Slowly push the IFP down into the shock body until the
IFP locator tool bottoms-out on the tube.
11. Install the gas fill port bleed screw into the body cap.
Install a new body cap o-ring, and then reinstall the
body cap. Tighten securely.
NOTE: The IFP should now be set in the correct
position inside the shock body.