Shocks / Springs; Exploded View; Shock Removal / Installation; Shock Replacement - Polaris 2008 RZR Service Manual

BODY / STEERING / SUSPENSION

SHOCKS / SPRINGS

Exploded View

Spring
Shock

Shock Removal / Installation

1. Elevate the vehicle off the ground to relieve the suspension
load.
2. Remove the upper and lower fasteners retaining the shock
and remove the shock from the vehicle.
3. Reverse the procedure to reinstall the shock. Torque new
fasteners to 27-33 ft. lbs. (37-45 Nm).

Shock Replacement

1. Using a spring compressor, compress the shock spring far
enough to remove the spring retainer.
Shock Spring
Compressor Tool
2870623
2. Remove the spring and adjusting cam from the existing
shock and install components onto the new shock.
3. Compress the shock spring and install the spring retainer.
4. Reinstall the shock onto the vehicle and torque new
fasteners to 27-33 ft. lbs. (37-45 Nm).
5.24
27-33 ft. lbs.
(37-45 Nm)
Spring
Retainer
Adjusting Cam
27-33 ft. lbs.
(37-45 Nm)

DECAL REPLACEMENT

The following procedure involves the use of an
open flame. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials. Be sure the area to be
flame treated is clean and free of gasoline
or flammable residue.
Do not flame treat components that are installed
on the vehicle. Remove the component from the
vehicle before flame treating.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be "flame treated"
prior to installing a decal to ensure good adhesion. A bonus of
the flame treating procedure is it can be used to reduce or
eliminate the whitish stress marks that are sometimes left after
a fender or cab is bent, flexed, or damaged.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the
surface appears slightly glossy. This should occur after just
a few seconds of flame treating. Do not hold the torch too
close to the surface (2-3 inches from the flame tip is
recommended). Keep the torch moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the decal
surface to eliminate any air bubbles during the application.
WARNING
WARNING