Polaris Magnum 2x4 Service Manual page 335

BODY AND STEERING
FOX™
Shock Service
12. Unscrew the bearing cap completely and pull shock rod
and piston straight out to avoid seal or valve damage.
NOTE:
Be prepared to catch the valve assembly piston
ring. It may fall out when the valve assembly is removed
from the shock body.
13. Remove shock from vise, drain oil from shock body and
dispose of properly.
14.
Clean shock body with clean high flash point solvent and
dry thoroughly with compressed air. Inspect walls of
shock and reservoir body for wear or damage.
15. To clean the damper valve assembly, slide the jounce
bumper away from the top shock eye toward the valve
assembly. Position the holder with the valve assembly
facing upward.
CAUTION:
Be sure the shaft and tool are
clean and free of debris before installing the tool, or shaft
damage may result.
16.
Remove the valve assembly locknut to allow thorough
cleaning of individual valving washers. Clean with
solvent and dry thoroughly with compressed air.
CAUTION:
Pay close attention to the order of valving
washers and the direction of the holes in the valve piston.
All parts must be replaced in the same order as removed
to maintain proper dampening characteristics.
17. Remove and clean all valve washers and valve piston
with solvent and dry thoroughly with compressed air.
Assemble in the same order as removed.
18.
Replace lock nut with a new one (PN
1500016)
and
tighten to
18 ft.
Ibs.
CAUTION:
Locking properties of nut
will be reduced when nut is loosened or removed.
Replace lock nut before reassembly. Do not re-use old
nut.
19. Mount shock in vise a t a1 0° to 15° angle. Pour oil (PN
2870995 only) down the side of reservoir slowly until
level is equal in main shock body. Continue to fill
reservoir within 1/4/1 from top, and set the shock upright in
vise.
7/96
5.32
Valve Piston
Side with most holes toward
1
damper rod nut
Polaris Industries Inc.