2007-2011 IQ Service Manual Chapter 09
Contents
1. 2009 Shock Specifications Front Suspension Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH ROD FP 1 OIL VOLUME PSI IN IN IN 7043245 Ryde FX 18 00 11 80 6 20 49 6 92 Full 200 7043452 Walker Evans 18 00 11 73 6 26 625 2 00 Full 200 36mm Rod 7043446 Ryde FX 2 0 18 00 11 80 6 20 N A 5 75 Full Cylinder 47mm Body Cylinder 60 7043404 Walker Evans 18 00 11 75 6 25 1 124 N A 200cc ORTES Air Reservoir 325 Walker Evans 7043490 Ai 17 02 11 27 5 75 1 124 95cc 225 Front Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH me ROD IFP ae OIL VOLUME PSI IN IN IN 7043244 Ryde FX 12 12 8 61 3 52 50 4 68 Full 200 7043411 Walker Evans 11 55 8 17 5 38 625 1 30 Full 200 7043449 Walker Evans 12 34 8 84 3 50 50 4 625 Full 200 7043388 12 49 8 92 3 57 1 12 N A 60cc 217 5 Rear Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH ROD b OIL VOLUME PSI IN IN IN 7043177 Fox 15 60 10 56 5 04 50 1 22 7043385 Walker Evans 15 60 10 56 5 04 625 2 25 7043316 Ryde FX 15 60 10 60 5 00 50 1 60 Full 200 7043403 Walker Evans 16 71 10 96 5 75 50 2 25 7043366 Walker Evans 16 71 10 96 5 75 50 6 75 9922854 2007 2011 IQ Service M 9 1 5 lt gt POLARIS 2010 Polaris Sales 222 Shocks 2009 Shock Valve Shim Stack Configurations NOTE All measurements are in inches 20092. 9 24 OPTIONAL SHOCK SETTINGS d o XA eee ees 9 25 WALKER EVANS MONOTUBE IFS AIR 9 25 WALKER EVANS IFS AIR REMOTE RESERVOIR PIGGYBACK SHOCK 9 25 RYDE FX AIR 2 05 9 26 SHOCK MAIN TENANGE re nr ethan PEU eri TO aes nue 9 27 RYDE FX AIR 2 0 SHOCK DISASSEMBLY 9 27 RYDE FX AIR 2 0 SHOCK ASSEMBLY 9 28 WALKER EVANS AIR SHOCK DISASSEMBLY 9 31 WALKER EVANS AIR SHOCK ASSEMBLY 9 31 WALKER EVANS AIR PIGGYBACK SHOCK DISASSEMBLY 9 32 WALKER EVANS AIR PIGGYBACK SHOCK ASSEMBLY 9 33 WALKER EVANS REMOTE RESERVOIR PIGGYBACK SHOCK DISASSEMBLY 9 34 WALKER EVANS REMOTE RESERVOIR PIGGYBACK SHOCK ASSEMBLY 9 35 RYDE FX REMOTE RESERVOIR SHOCK DISASSEMBLY 9 36 RYDE FX REMOTE RESERVOIR SHOCK ASSEMBLY 9 38 RYDE FX MONO TUBE SHOCK DISASSEMBLY 9 40 RYDE FX MONO TUBE SHOCK ASSEMBLY 9 41 FOX PS gt DISASSEMBLY ina ef Law ea tenes 9 42 FOX PS 5 ASSEMBLY e eo eer epe NR Geach E Leeder aves 9 43 TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 9 1
3. SHOCK 7043177 7043246 7043266 7043205 7043216 7043235 620 x 093 950 x 050 990 080 82555062 625 x 065 950 x 050 700 x 010 a 800 x 012 950 x 050 700 x 010 gt 800 008 800 x 010 620 x 093 900 x 012 900 x 008 800 x 010 2 900 x 008 900 x 010 1 125 x 093 1 000 x 012 1 100 x 015 900 x 010 1 000 x 010 1 00 x 010 1 100 x 010 1 100 x 012 1 100 x 015 1 00 x 010 LU 1 100 010 1 10 x 010 1 250 x 012 tr 1 250 x 010 700 x 006 1 10 x 010 1 250x 010 1250 008 700x 008 2000008 1 25 x 012 i 1 250 x 008 1 25 x 012 1 Piston Orifice 093 070 076 082 055 040 1 30 x 010 1 300 x 006 1 300 x 008 1 25 x 010 1 300 008 1 250 008 1 250 x 008 700 x 010 1 300 x 008 1 30 x 010 1 300 x 008 900 x 010 1 25 x 010 800 x 008 1 10 x 008 1 300 x 006 1 000 x 006 1 250 x 010 1 10 x 008 o 1 250 x 012 900 x 008 800 x 010 o 1 100 x 008 1 100 x 008 1 10 x 008 1 100 x 012 1 10 x 008 1 300 x 010 1 100 x 010 1 000 x 008 1 00 x 010 tc 1 000 x 010 1 00 x 010 1 300 x 008 Q 1 100 x 012 900 x 010 900 x 010 700 x 015 900 x 010 1 300 x 008 1 000 x 010 700 x 015 800 x 008 90055010 700 x 015 000005 800 008 900 008 700 x 010 o 1 125 093 700 x 015 700 1015 700 008 1 125 x 093 875 x 090 1 1 125 x 093 i 125 c 093 625 x 065 1 875 x 090 NOTE Valve shim stacks listed as they would appear on the shaft w
4. Shocks SPECIAL TOOLS Shock Rebuilding Tools Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201639 Shock Shaft Seal Protector 50 Diameter 2201640 Shock Shaft Seal Protector 625 Diameter 2870623 Shock Absorber Spring Compression Tool 2870803 Shock Spring Pre Load Adjustment Tool PS 45259 Gas Fill Tool Ryde FX Shock Special Tools PART NUMBER DESCRIPTION 5 45259 Gas Fill Tool and Gauge Incl 5 needles PS 45259 1 Gas Fill Needles replacement pack PS 45259 2 Gas Fill Gauge replacement PS 45260 Lower Retainer Wrench PS 45261 IFP Positioning Extraction tool PS 45262 Cylinder Head Wrench PS 45263 Wear Band Tool PS 45629 Arvin Shock Body Holder PS 45280 Shock Collar Tool PS 45821 Shock Reservoir Holder FOX Shock Special Tools PART NUMBER DESCRIPTION 2871021 Shock Body Holding Tool 2871352 Shock Rod Holding Tool 50 Diameter Rod 2872429 Shock Rod Holding Tool 625 Diameter Rod 2871232 Fox Shock Spanner 2871351 Fox Shock IFP Depth Tool PS 44925 Fox Inner Tube Puller PS 2 MINATI 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS Shocks VALVE SHIMS motion Refer to the appropriate parts manual for a nes complete listing of shock parts Shock shim stacks can be adjusted to control the amount of fluid that is forced by as the piston travels through its
5. 012 1875 x 090 625 x 065 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 9 13 Shocks 2008 Rear Track Shocks SHOCK 7043177 7043216 7043316 7043366 625 065 620 x 093 700 x 015 a 800 x 012 7 x 012 800 x 015 900 x 012 9 012 1900 x 015 o 1 000 x 012 10 00 1 0 x 012 1 00 x 015 1 100 012 de 1 1 x 012 1 10 x 015 tr 1 250 x 010 1 25 x 012 1 20 x 015 1 250 x 010 1 25 x 015 1 25 x 015 Piston Orifice 093 055 081 065 1 30 x 015 1 20 x 012 1 300 x 008 1 00 x 012 z ROB 1 300 x 008 1 3 x 008 BUD o 1 300 x 006 1 1 x 006 1 000 x 006 1 30 x 012 o 800 x 010 1 0 x 006 0 1 100 008 1 25 x 012 d 1 300 x 010 7 x 006 1 100 x 010 1 20 x 012 oc 1 300 x 008 1 25 x 008 1 100 012 1 10 x 012 1 300 x 008 1 1 x 008 1 000 x 010 5000 00 1 00 x 015 900 x 010 Dire pd Sain 1200 x 015 1 125 x 093 800 x 015 700 x 012 625 x 065 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 9 14 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Shocks
6. Ryde FX Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1700080 0 700 1700086 0 800 0 004 1700092 0 900 1700081 0 700 1700087 0 800 1700093 0 900 1700121 1 000 0 006 1700129 1 100 1700134 1 250 1700139 1 300 1700094 0 900 1700122 1 000 1700130 1 100 0 008 1700135 1 250 1700140 1 300 1700082 0 700 1700088 0 800 1700083 0 700 1700089 0 800 1700095 0 900 1700126 1 000 0 010 1700131 1 100 1700136 1 250 1700141 1 300 1700084 0 700 1700090 0 800 1700096 0 900 1700127 1 000 0 012 1700132 1 100 1700137 1 250 1700142 1 300 1700085 0 700 1700091 0 800 1700120 0 900 1700128 1 000 0 015 1700133 1 100 1700138 1 250 1700143 1 300 TERRAIN DOMINATION 9 3 PoLARIS MC Te Shocks Fox Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1500055 0 700 1500054 0 800 1500053 0 900 1500048 1 000 0 006 1500049 1 100 1500050 1 250 1500052 1 300 1500029 0 700 1500028 0 800 1500033 0 900 1500032 1 000 0 008 1500031 1 100 1500051 1 250 1500030 1 300 1500044 0 700 1500047 0 800 1500046 0 900 1500045 1 000 0 010 1500027 1 100 1500026 1 250 1500062 1 300 1500056 0 700 1500057 0 800 1500058 0 900 1500059 1 000 0 012 1500060 1 100 1500078 1 250 1500079 1 300 1500081 0 7
7. 006 7043205 7043441 900 x 006 E 800 x 006 mene 700 x 012 700 x 010 o 700 x 006 a 800 010 800 x 012 625 x 065 2 900 x 012 5 900 x 010 875 x 090 1 00 x 010 1 00 x 012 a 1 10 x 010 1 10 x 012 1 10 X 025 ra 1 25 x 012 1 00 X 015 OR S 1 25 x 012 Shaft Bleed 082 070 rifice 1 30 x 010 1 25 x 010 700 x 010 1 30 x 012 1 10 x 008 1 10 x 010 o 900 x 008 1 00 x 008 1 10 x 008 1 25 x 012 1 00 x 010 1 10 x 010 900 x 010 900 x 008 8 8 00x 008 800 x 010 700 x 008 700 x 012 625 x 065 875 x 090 9 24 9922854 2007 2011 IQ Service Manual e POLARIS 2010 Polaris Sales Inc Shocks OPTIONAL SHOCK SETTINGS Walker Evans Monotube IFS Air Shock NOTE When servicing any air IFS shock recharge both shocks to the same pressure setting Raise the vehicle off the ground or remove shocks completely Discharge the shock gas pressure completely before refilling the shock with nitrogen Raise the shock nitrogen gas pressure within each shock in 2 5 psi increments and keep the fill tool needle installed in the charge port for at least 30 seconds to allow the gas pressure to stabilize Perform work on shocks when shocks and nitrogen gas supply tank are at room temperature 70 F 21 C Walker Evans IFS air shocks can be configured using the most current valve stack and nitrogen pressure settings Updating 2007 shocks to current specifications will r
8. SOEK D MODEL LENGTH LENGTH ROD IFP DEPTH OIL VOLUME PSI NUMBER IN IN IN IN IN 7043244 12 12 8 61 3 52 50 4 68 Ryde FX 7043437 12 48 8 92 3 59 49 4 806 7043449 12 34 8 84 3 50 50 4 625 200 7043535 Walker Evans 11 55 8 17 3 38 50 2 5 7043549 12 00 8 60 3 50 50 7043388 Walker Evans Air 12 49 8 92 3 57 1 12 N A 60cc 217 5 Rear Track Shocks EXTENDED COLLAPSED SHOCK MODEL LENGTH LENGTH ROD ROBE OIL VOLUME PSI NUMBER IN IN IN IN IN 7043177 Fox 15 60 10 56 5 04 50 1 22 7043385 15 60 10 56 5 04 625 2 25 7043403 2 25 7043366 Walker Evans 16 71 10 96 5 75 50 6 75 Full 200 7043600 2 25 7043205 15 60 10 56 5 04 625 2 25 7043441 Ryde FX 16 70 10 96 5 75 50 6 65 TERRAIN DOMINATION 9 19 POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Shocks 2010 Shock Valve Shim Stack Configurations NOTE All measurements are in inches 2010 IFS Shocks SHOCK 7043245 7043534 7043599 7043490 625 x 065 625 x 065 wee 7 012 7 x 008 7 x 012 a 7 x 010 8x 012 S 8 x 008 8x 012 8x 010 9x 012 2 9 x 008 9 x 012 9 x 010 1x 012 1 x 008 1x 012 1 010 1018 1 1 x 008 1 1 012 1 1 x 010 1 2 x 015 1 25 x 008 1 2 x 012 1 2 x 010 1 25 x 010 SON 1 25 x 015 Piston d Shaft Bleed 082 Shaft Bleed 082 Orifice Piston Bleed 052 Piston Bleed 040 1 3 x 006 dass ane 1 3 x 010 1 3 x 015 1 x 008 1 2 x
9. 008 o 9x 008 1 3 x 012 22 1 25 x 012 9x 008 9x 006 1 25 x 008 1 2 x 012 18542 1 1 x 008 1 25 x 012 1 25 x 010 5 1 1 x 008 1 1 x 012 1 0 x 008 1 1 012 1 1 x 010 z 1x 010 1x 012 9 x 010 1x 012 1 0 x 010 9 010 9x 012 d IE 8 x 008 9x 012 9 x 010 8x 008 8 012 7 012 8 010 8x 010 7x 012 2 875 x 100 875 x 100 875 x 100 42 1 3 x 025 1 3 x 025 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 9 21 2010 Polaris Sales Inc Shocks 2010 Rear Track Shocks 7043177 7043385 7043600 7043403 7043366 7043205 7043441 625 065 625x 065 625x 065 065 620 093 625x 065 7 x 015 7 x 015 700 015 7752 040 7 x 012 a 8x 012 7 x 010 8 x 015 8 015 800 x 015 8 8 x 012 lt 9 x 012 8x 010 9 x 015 9 015 900 x 015 22 9 x 012 fe 1 x 012 9 x 010 1 x 015 1 x 015 1 00 x 015 Va aie 1 0 x 012 m 1 1 x 012 1 x 010 1 1 x 015 i1x015 40001521 1 1 x 012 cc 1 25x 010 1 1x 010 1 2x 015 1 2x 015 1 20x 015 35 008 1 25 x 012 1 25x 010 125x 010 125x 015 125 015 125 015 jor 125x 012 125x 015 125 x 015 1 25x 015 mi Piston Shaft Bleed Shaft Bleed 093 ub 052 052 065 ds 070 1 3 x 012 1 3 x 015 22 1 3 x 010 Tm 1 3 0
10. 015 2 1 1 x 006 1 2 x 060 08 224 9 x 008 1 2 x 010 225 1 2 x 008 1 1 x 015 9 1 25 x 006 1 1 x 006 1 1 x 008 1 1 x 010 1 1 x 008 1 x 006 1 x 008 1x 015 1 x 006 9 x 006 E nod acai 9 x 006 8 x 006 ros 2 8 x 008 8 x 015 8 x 006 7 x 006 oy Bie 7x 015 7 015 2 875 x 090 875 x 090 m 1 1 X 025 1x 025 x 1X 015 1 x 025 625 X 065 625 x 065 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up 9 20 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION POLARIS Shocks 2010 Front Track Shocks SHOCK 7043244 7043449 7043388 7043437 7043535 7043549 625 065 7X 015 8 015 625 x 065 9 x 015 2 7x 010 7x 012 1 x 015 7 010 2 7x 010 8 x 012 8 012 11 015 8 010 20 8 010 9 x 010 9x 012 1 1 015 9 x 010 pego 9x 010 Q 1 x 010 1 x 012 1 2 x 015 1 0 x 010 org 1 0 x 010 1 1 010 1 1 012 12 015 1 1 012 1 1 x 010 1 25 x 010 1 2 x 012 1 2 x 015 1 25 x 010 1 25 x 010 1 25 x 012 1 25 x 015 Eus 1 25 x 015 1 25 x 015 7 x 015 Piston 070 052 040 070 070 070 Orifice 7X 015 7 x 010 1 3 x 010 1 2 x 010 1 3 x 008 1 3 x 008 1 3 x 008 1 1 010 1 3 x 006 1 25 x 008 1 25 x 008 S 1 1 x 006 1x 010 2 9x 008 1 1 x 008 1 1 x
11. 300 006 1900 x 008 1 00x 012 1 300 x 008 1 300 x 008 1 00 x 012 1 20x 015 2222 o 1 100 x 006 1 00 008 1000x010 1 20x 006 1 100x 006 1 250 x 008 1 20 x 006 120 010 25052 D 800 x 008 800 008 1250x 008 012 800 008 900 006 900 x 012 1022015 2222505 0 1 250 x 006 1 250 008 900 010 140 006 1 250x 006 1 300 x 010 1 10 x 006 1 100 008 110008 1 100 008 100 006 1 100x 008 1 250 x 008 1 00 x 006 1 00x 015 21200506 1 000 x 006 1 000 008 1 000 008 006 1000 006 1 100 x 010 900 x 006 900 010 1400 015 900 x 006 300 008 900 008 400 006 900x 006 1 000 012 800 x 006 800 x 010 an 5 800x 006 700 015 800 008 700 006 800x 006 900 012 700 x 006 20050101 O 700 x 015 700 ODE 625x 065 700x 015 800x 012 625 x 065 625 065 800 1 125 x 093 1 125 x 093 700 x 010 875 x 090 875 x 090 130 150 SANS NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 9 9 Shocks 2007 Front Track Shocks 7043204 SHOCK 7041975 7043142 7043244 7043267 7043234 620 x 093 620 x 093 625 065 25 24 700 x 015 625 x
12. Inc POLARIS Shocks 2008 Shock Valve Shim Stack Configurations NOTE All measurements are in inches 2008 Front Track Shocks NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 2008 IFS Shocks SHOCK 7043244 7043365 625 x 065 SHOCK 7043245 7043315 043364 7x 015 7043490 8x 015 625 x 065 ae 9x 015 700 x 008 100X012 gt 900 x 010 eos 800 x 012 1 1 015 2 800 x 008 7 010 8100 1013 a 1 000 x 010 201 gt 1900 x 008 9x 010 10050129 1 100 010 1 000 x 008 1 1 x 010 t 1 250 010 pra 1 10 x 015 1 25 x 015 1 100 008 1 25 015 oc 2 1 20 x 015 1 25 x 015 1 25 010 1 25 x 015 1 25 x 015 Piston Orifice 070 052 Piston 060 041 052 1 3 x 010 Orifice 1 1 x 010 1 30 x 015 z 1 300 x 008 9 x 012 1 300 x 008 1 20 x 015 1 100 x 006 7 x 012 z E 5 1 100 x 006 o 900 x 008 1 8 x 012 o 1 4 x 012 1 20 x 010 9 TA 800 x 008 1 250 x 008 1 2 x 012 o 9x 012 1 10 x 015 0 1 250 006 13 x 010 1 10 x 010 oc 1 100 x 008 1 1 x 012 1 100 008 pe 1 000 x 010 1 0 x 012 oc 1 1 x 010 1 00 x 015 0x Q 1 000 x 006 900 x 010 9 012 7 x 010 900 x 015 o 900 x 006 800 x 008 8x 012 BOO 2006 7 x 010 800 x 015 p 700 x 015 7
13. Manual gt POLARIS 2010 Polaris Sales Inc 9 44
14. pressure wash your shock as this can force water and debris inside which will damage the seals Dry the shock assembly with compressed air if available or use clean towels Use a 3 32 Hex Key to remove the button head screw from the FOX air valve in the shock body Securely clamp Fox Nitrogen Safety Needle in vice Point air valve away from face and body when CAUTION charging or discharging any shock 9 42 Insert the Fox Safety Needle squarely into center of gas valve Using a blunt object depress the air valve core to release pressure When the shock is FULLY DISCHARGED pull reservoir away from the Fox Safety Needle in a straight smooth motion Clamp the body end eyelet of the shock securely in vice with shaft side up Using the 1 3 8 wrench loosen and unscrew the bearing assembly from the shock body If the body cap unscrews instead of the bearing that is OK You will need to remove both for this rebuild procedure Clamp the shock in the vice using the body clamp blocks If the bearing is still in the body use the 1 3 8 end wrench to loosen and un thread the bearing If the body cap is what needs removal use the large crescent wrench to loosen and unthread the body cap Remove the shaft assembly from the body tube and place on a clean lint free paper towel Remove the shock from the vice and pour shock oil from body tube into a proper disposal container Do not re use o
15. remove the bleed screw from the IFP inside the reservoir Verify the o ring comes out with the screw 8 Use a pliers to remove the IFP from the reservoir Verify the wear band and o ring come out with the IFP 9 Pour out all of the shock oil into an appropriate storage container Dispose of oil properly NOTE Do not reuse shock oil TERRAIN DOMINATION POLARIS 10 11 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Shocks Place the shock rod in a soft jawed bench vise Remove the valve shim stack and piston nut Remove the shims and piston as they are arranged on the shaft With the shock disassembled inspect the following items Piston rod for straightness nicks or burrs Cylinder head assembly bearing Inside of shock body for scratches burs or excessive wear Teflon piston and IFP wear band for cuts chipped or nicked edges or excessive wear O rings for nicks cuts or cracks Valve discs for kinks or waves Hose for kinks or cuts 9 37 Shocks Ryde FX Remote Reservoir Shock Assembly 1 Install the shock rod in a soft jawed bench vise Reassemble the valve shim stacks and piston in the order in which they were removed Torque nut to specification DO NOT OVERTIGHTEN THE NUT DAMAGE TO THE CAUTION SHOCK ROD MAY OCCUR ey T Shock Rod Lock Nut Torque 15 20 Ft Lbs 21 28 Nm Secure the shock body i
16. should be installed at this time if seals or o rings are damaged or worn 11 Place the shock rod in a vise so that the threaded part is facing upward 12 Place the valve stack on a clean shop towel in order of removal NOTE Place the valve stack on a clean shop towel in case you have to move them This will also help when assembling them back onto the shock rod TERRAIN DOMINATION POLARIS Shocks 13 Inspect the valves for kinks waves pits or foreign material 14 Inspect the piston wear band and replace if damaged 5 or worn 6 Walker Evans Remote Reservoir Piggyback 7 Shock Assembly 1 Secure the shock rod in a vise with the threads of the facing up 9 2 Place the compression valve stack on the rod in the reverse order of disassembly 3 Place the valve piston on top of the compression stack 10 11 4 Place a new lock nut onto the shock rod Torque the new lock nut to specification ey T Lock Nut Torque 14 ft lb 19N m IMPORTANT Do not over torque or damage to the valve stack can occur TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHRIS 2010 Polaris Sales Inc Secure the shock body by its lower mount Set the compression damping adjustment selector to position 1 Fill the shock body and remote reservoir 1 2 full of Walker Evans 5w shock oil PN 2874522 Apply a thin film of oil to the IFP o ring and floati
17. to prevent spraying gas and oil place rag over top the pressure valve assembly and slowly loosen the valve assembly with slotted screw driver three full revolutions allowing all the gas pressure to escape past the pressure valve assembly O ring Allow all the gas pressure to escape before proceeding with the removal of the pressure valve assembly Pressurized gas and shock oil could eject the valve assembly from the cylinder resulting in bodily injury Using a slotted screwdriver remove the pressure valve assembly from the lower end mount Account for an O ring Using an adjustable face spanner PN PS45262 fully loosen and remove cylinder head assembly Pour the oil out of the shock body Discard old oil into an approved storage container and dispose appropriately Never reuse damper oil during shock rebuild Using the F P extraction tool thread the tool into the LF P and pull upwards removing the I F P from the shock body Account for wear band and an O ring Note Not applicable for emulsion shock Clean the inside of the shock body using clean parts cleaning solvent and blow dry using compressed air Place the shock piston rod upper mount in bench vise begin piston and valve removal Arrange parts removed in the sequence of disassembly The piston should have the flat slots facing the nut end as highlighted in black Items to inspect Piston rod for straightness nicks or burrs Cylinder Head Assembly DU Bearing clean
18. x 012 1 015 gt 8 012 508 8 012 1 1 x 015 9 x 010 pios 9 x 012 1 1 x 015 9 1x 010 oto 1x 012 1 2 x 015 1 1 x 010 idola 1 1 x 012 1 2 x 015 oc 1 25 x 010 200 12 012 1 2 x 015 em 1 25 x 012 1 25 x 015 1 25 x 015 1 25 x 015 7 x 015 Piston 070 082 052 040 Orifice 7X 015 7 x 010 as ais 1 3 x 012 13501 1 1 012 1 3 010 9 x 012 5 ut x ps 1 2 x 010 po a 7x 008 A 1 1 x 010 1 3 x 015 o 9x 008 1 3 x 012 o 1x 010 1 2 x 015 H 1 25 x 008 1 2 x 012 9 x 010 1 2 x 015 oc 1 1 x 008 1 1 x 012 8 010 1 1 015 1x 010 1x 012 7 010 1 015 0 9 x 010 9 x 012 9 Rape 625 x 065 apte 9 x 015 875 x 100 oe 8x 015 7 x 012 Bd nb 7 x 012 1 3 x 025 1 3 x 025 1 3 x 025 NOTE Valve shim stacks listed as they would appear on the when shock rod is locked in table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Shocks 2009 Rear Track Shocks SHOCK 7043177 7043385 7043316 7043403 7043366 625 x 065 625 x 065 620 x 093 2 7 015 700 x 015 800 x 012 2 7x 012 8 x 015 800 x 015 900 x 012 2 9 x 012 9 x 015 900 x 015 o 1 000 x 012 10 012 1x 015 1 00 x 015 m 1 100 x 012 21 1 1 012 1 1 015 1 10 015 1 250 x 010 4 1 25 x 012 12 x 015 1 20 x 015 1 250 x 010 220 1 25 x 015 1 25 x 015 aa 1 25 015 1 25 x
19. 00 1800247 1 200 1800248 1 300 on 1800249 1 450 1800250 1 500 1800251 1 550 1800252 900 1800253 1 000 1800254 1 100 1800255 1 200 1800256 1 300 qe 1800257 1 450 1800258 1 500 1800259 1 550 1800260 900 1800261 1 000 1800262 1 100 1800263 1 200 1800264 1 300 PR 1800265 1 450 1800266 1 500 1800267 1 550 1800268 1 000 1800269 1 100 090 WASHERS 1800270 1 250 1800271 1 300 025 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc MINATI POLARIS Shocks NOTE The rebound and compression valve stacks Valve Shim Arrangement will always be positioned as shown in the Shown below is an example of how valving stacks are illustration regardless of how the shock assembly is arranged installed on the snowmobile FULLY COMPRESSED SHOCK ROD FULLY EXTENDED PISTON SHOCK ROD 224 RS ENN ZZ RESIN 52127 REBOUND VALVE STACK COMPRESSION VALVE STACK Piston Orientation NOTE On some Walker Evans shocks the piston is color coded The face of the piston with the greater number of relief COMPRESSION SIDE ports will always face the rebound valve stack Red REBOUND SIDE Relief Port Faces Rebound Stack Faces Compression Stack 9 7 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLARIS 2010 Polaris Sales Inc Shocks SPECIFIC
20. 00 1500082 0 800 1500083 0 900 1500084 1 000 0 015 1500085 1 100 1500086 1 250 1500087 1 300 9 4 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION POLARIS Shocks Walker Evans Shock 3 8 Valve Part Numbers PART NUMBER SIZE THICKNESS 1800051 700 1800075 800 1800076 900 1800077 1 000 006 1800078 1 100 1800079 1 200 1800080 1 300 1800081 700 1800082 800 1800083 900 1800084 1 000 cd 1800085 1 100 1800086 1 200 1800087 1 250 1800088 1 300 1800052 700 1800053 800 1800054 900 1800055 1 000 en 1800056 1 100 1800057 1 200 1800379 1 250 1800058 1 300 1800059 700 1800060 800 1800061 900 1800062 1 000 iiz 1800063 1 100 1800064 1 200 1800089 1 250 1800072 1 300 1800066 700 1800067 800 1800068 900 1800069 1 000 dis 1800070 1 100 1800380 1 200 1800071 1 250 1800072 1 300 1800090 1 000 1800091 1 100 Se 1800092 1 200 1800093 1 300 1800050 625 065 1800204 875 090 TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 9 5 Shocks Walker Evans Shock Valve Part Numbers 7 16 1 0 PART NUMBER SIZE THICKNESS 1800244 900 1800245 1 000 1800246 1 1
21. 015 Piston N A Orifice 093 082 Shaft Bleed a 182 065 1 3 x 006 1 3 x 015 422 1 300 x 008 1 25 006 1 3 019 1 00 x 012 z 52 7 x 010 1 3 x 008 1x 010 2 ore 1 1 x 008 1 1 x 006 1 25 x 015 BUE 2 1 000 006 1 30 x 012 0 9 x 008 1 0 x 006 1 25 x 015 9 1 100 x 008 1 25 x 012 o 1 1 x 008 7 x 006 12 x 015 1 100 x 010 1 20 x 012 1x 010 1 25 x 008 1 1 x 015 E 1 100 x 012 1 10 x 012 9 x 010 1 1 x 008 1x 015 1 000 x 010 BE 1 00 x 015 o 900 x 010 8208 Sex TR 900 x 015 7 008 7 x 010 8 x 015 1 125 x 093 800 x 015 625 x 065 7x 012 id 875 x 090 1 2 x 100 oni pis NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 9 18 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Shocks 2010 Shock Specifications Front Suspension Shocks EXTENDED COLLAPSED SHOCK MODEL LENGTH LENGTH STROKE ROD OIL VOLUME PSI NUMBER IN IN IN IN IN 7043245 Ryde FX 11 80 6 20 49 6 92 7043534 18 00 Full 200 Walker Evans 11 72 6 27 625 2 00 7043599 7043490 Walker Evans Air 17 02 11 27 5 75 1 124 N A 95cc 225 Front Track Shocks EXTENDED COLLAPSED SHOCK
22. 065 22 a 800 x 015 800 x 015 700 x 012 2 900 x 012 800 x 012 800 x 015 900 x 012 800 x 015 800 x 012 2 1 00 x 010 900 x 010 900 x 015 ris 900x 012 500 010 900 x 012 900 x 012 2 ca i 000 x 010 1990x 1 000 x 010 1 000 x 012 2025 010 1 100 x 010 1 10 x 015 Mou UE go 1 100 x 012 AUN 800 x 008 eo 800 x 006 1 200 x 012 1 250 x 008 1 250 x 008 290 Piston Orifice 070 078 070 070 082 052 1 30 015 1 30 x 015 z 1 300 006 4 300x 008 1 300 x 010 1 30 x 012 18 018 1 300 x 008 1 250 x 008 1 20 x 015 1 100 006 1 250 x 008 1 20 x 012 2 1 000x 006 900 008 1 10 x 015 D 900 x 008 1 100 x 008 1 10 x 012 P 1 300 008 1250x 008 25 1 00 x 015 o 250 x 008 900 x 008 1 00 x 012 1 100 x 010 1 100 x 008 900 x 015 1 100 x 008 800 x 008 900 x 012 1 000 008 900 x 008 800 x 015 1 000 x 010 700 x 008 800 x 012 900x 008 700x 012 700 x 015 5 900 x 010 700 x 012 700 x 012 800 008 700 012 900 010 ee 2 1 30 x 025 1 125 093 200 1 30 x 025 875 x 090 1 30 x 025 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 9 10 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 2007 Rear Track Shocks Shocks
23. 10 1 1 x 012 a any io Meee 010 155 4 82253010 9x 012 1x 010 phi 7 x 010 1 3x 012 133 008 1 253 015 1 28 0187 Si 11x08 1 1 x 010 D 1 008 9 x 008 1 25 015 4 25x 015 oe 012 9 x 008 1 0 x 008 aie 1 1 x 008 1 2 x 015 12 015 LAS one 10081 125x012 iS 1x 010 1 1 x 015 io 1 010 1 1 x 010 200 9 x 010 1x 015 1x 015 1 008 815 9 x 010 9 x 008 9 dx 610 8 x 010 9 x 015 9 x 015 ao 015 8 x 008 8x 010 te 550010 8 x 015 8 015 BORSE 7 x 008 7 x 012 NOS 875 x 090 7 x 012 7 012 ox 12 25 058 1 2 x 100 18x 300 Pas en 2875 090 e 1 1 x 025 1 1 x 025 1 1 x 025 1 015 1 1 025 1 1 x 025 1x 015 1x 025 1 x 025 7 010 1 x 025 1 x 025 o 875 090 875x 090 875x 090 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 9 22 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Shocks 2011 Shock Specifications Front Suspension Shocks SHOCK EXTENDED COLLAPSED SHOCK PART MODEL LENGTH LENGTH STROKE ROD DEPTH Le PSI IN IN VOLUME NUMBER IN IN IN 7043534 Walker Evans 18 00 11 72 6 27 625 2 00 Full 200 Front Track Shocks SHOCK EXTENDED COLLAPSED SHOCK PART MODE
24. ATIONS 2007 Shock Specifications Front Suspension Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH Hs OIL VOLUME PSI IN IN IN 7042258 Ryde FX 18 00 11 8 6 2 49 6 92 Full 200 7043245 Ryde FX 18 00 11 8 6 2 49 6 92 Full 200 7043141 Fox 18 00 11 8 6 2 50 1 42 Full 200 7043268 LH 7043269 Fox 18 00 11 8 6 2 49 2 55 Full 200 RH 7043095 Walker Evans 18 00 11 738 6 27 625 2 25 Full 200 7043090 Ryde FX 17 00 11 20 5 80 49 6 54 Full 200 7043082 Ryde FX 16 25 12 76 5 25 49 6 27 Full 280 7043206 Walker Evans 18 00 10 13 6 26 625 2 25 Full 200 Walker Evans 215 7043233 Air 17 02 11 27 5 75 1 124 N A 95cc 220 225 Opt Front Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH ih R OiL VOLUME PSI IN IN IN 7041975 Ryde FX 12 10 8 60 3 5 50 4 61 Full 200 7043142 Fox 12 51 8 92 3 59 150 840 200 7043244 Ryde 12 12 8 61 3 52 150 4 68 Full 200 7043267 Fox 12 07 8 63 3 44 50 1 8 Full 200 7043204 7043383 Walker Evans 12 10 8 60 3 50 625 2 25 Full 200 Walker Evans 215 7043234 Air 12 49 8 92 3 57 1 124 N A 70cc 210 220 Opt NOTE Original PN subs to number Reference new PN s specifications when servicing Rear Track Shocks SHOCK PN MODEL dm eee a pie iz oe OiL VOLUME PSI IN IN IN 7043177 Fo
25. IFS Shocks SHOCK 7043245 7043452 7043315 7043404 7043490 625 065 7 x 012 625 x 065 63 x 063 8x 015 7 x 012 a 7x 010 00 9 x 015 8x 012 z 8 x 010 S 1x 015 9 x 012 2 9 x 008 9 x 010 9 x 010 1 1 015 1x 012 5 1 x 008 1 1 x 010 m een 1x 010 UE dc 1 2 x 015 1 1 015 oc 2200 1 1 x 008 FOR 1 2 x 015 1 2 x 015 1 2 x 008 1 25 x 015 1 25 x 010 1 25 x 015 1 25 x 015 015 Piston 052 Orifice 060 082 Shaft Bleed 041 040 052 7 x 010 X006 7 012 1 3 x 015 1 3 x 008 1 012 1 3 x 015 1 2 x 015 z 1 1 x 006 1 2 x 006 14 x 012 1 2 x 015 1 2 x 010 8 x 008 9 x 012 o 9 x 012 1 2 x 012 1 1 x 015 E 1 25 x 006 1 1 x 006 1 3 x 010 1 1 015 1 1 x 010 1 1 x 008 1 x 006 oc 1 1 x 010 1 1 x 012 1x 015 1 006 9 x 006 522 aie 9 x 006 8 x 006 7 x 010 015 9 v pe 7 x 010 9 x 015 8 015 8 x 006 7 x 006 8x 015 7 x 015 7 x 015 625 x 065 cuir 7 x 010 1875 x 090 RE 875 x 090 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION POLARIS 9 16 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 2009 Front Track Shocks Shocks SHOCK 7043244 7043411 7043449 7043388 625 x 065 x 015 8 015 625 065 9 x 015 7 x 010 7
26. L LENGTH LENGTH STROKE ROD or PSI IN IN VOLUME NUMBER IN IN IN 7043676 Ryde FX 12 45 8 90 3 56 4 80 50 Full 200 7043717 Walker Evans 12 10 8 60 3 50 4 69 Rear Track Shocks SHOCK EXTENDED COLLAPSED SHOCK PART MODEL LENGTH LENGTH STROKE ROD IFP DEPTH oll PSI IN IN VOLUME NUMBER IN IN IN 7043205 Walker Evans 15 60 10 56 5 04 625 2 25 Full 200 u 7043441 Ryde FX 16 70 10 96 5 75 50 6 65 gt POLARIS 9922854 2007 2011 IQ Service Manual 9 23 2010 Polaris Sales Inc Shocks 2011 Shock Valve Shim Stack Configurations 2011 Front Track Shocks NOTE All measurements in inches SHOCK 7043676 7043717 Valve shim stacks listed as they would appear on the 700 010 700 010 shaft when shock rod is locked table vise eyelet 800x 010 800x 010 down threaded end up 5 900 010 900 010 1 00 010 1 00 010 2011 IFS Shocks 1 100 012 1 10 010 SHOCK 7043534 1 25x 010 1 25x 010 625 x 065 ak 070 070 700 x 010 2 800 x 010 1 30x 008 900 010 1 30 006 1 25 008 m 1 00 x 010 5 900x 008 1 10x 008 oc 1 10 x 010 2 1 25 012 900x 006 1 20 x 010 m 1 10x 008 1 25x 010 NE Shaft Bleed 082 1 00 008 1 10 010 Piston Bleed 052 0000 1 30 006 700x 012 800x 010 1 00 x 006 875 100 2 1 20 x 060 o 900 x 012 1 10 x 006 2011 Rear Track Shocks Td 1 00 x
27. Shocks CHAPTER 9 Shocks SPECIAL TOOLS 3 505 aec ed eee REY ae aoe BN eA eS Rees 9 2 SHOCK REBUILDING TOOLS 2 9 2 VALVE SHIMS ort o A EE ERO E ERR RR sea 9 3 RYDE FX SHOCK VALVE PART NUMBERS 9 3 FOX SHOCK VALVE PART NUMBERS 9 4 WALKER EVANS SHOCK 3 8 VALVE PART NUMBERS 9 5 WALKER EVANS SHOCK VALVE PART NUMBERS 7 16DI D 9 6 VALVE SHIM ARRANGEMENT 9 7 PISTON ORIENTATION 1 9 7 SPECIFICATIONS Garcia OU meer EA 9 8 2007 SHOCK SPECIFICATIONS 9 8 2007 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 9 2008 SHOCK SPECIFICATIONS 9 12 2008 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 13 2009 SHOCK SPECIFICATIONS 9 15 2009 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 16 2010 SHOCK SPECIFICATIONS 2 1 9 19 2010 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 20 2011 SHOCK SPECIFICATIONS 1 9 23 2011 SHOCK VALVE SHIM STACK CONFIGURATIONS
28. and rock the skis back and forth to verify issue Determine if the shock is leaking or has leaked an oil then determine why Look for shaft damage and replace the shaft and seal if damage is found If no oil leaks are found verify there are no gas leaks at the charge ports Replace the charge ports as required After inspecting both shocks recharge both shocks to the desired pressure settings and specifications TERRAIN DOMINATION POLARIS Shocks SHOCK MAINTENANCE 4 Using a flat blade screwdriver carefully loosen both pressure valve assemblies counter clockwise two full Ryde FX Air 2 0 Shock Disassembly rotations Allow all of the nitrogen gas to fully escape past each pressure valve assembly o ring A WARNING Before servicing a gas shock it is important that all the gas pressure be discharged from the shock Nitrogen gas is under extreme pressure Protective eye wear must be worn at all times to avoid risk of injury while servicing shocks or using compressed air CAUTION 5 After all of the nitrogen gas has been allowed to escape from the shock remove both pressure valve assemblies 4 Always clamp the lower mount of the shock in a vise Any other method of securing the shock body may deform the shock body cylinder 1 Remove the shock from the snowmobile Wash the entire shock assembly in parts cleaner then dry with compressed air or a clean shop towel 2 Remove l
29. b of torque DO OVER TORQUE If assembly MAy PISTON excessive torque is applied damage to the piston original position This must not occur if the damper is and valves expected to perform as designed 2 Secure the shock body by its lower mountinvise The 11 Using an open face spanner wrench tighten cylinder use of soft jaws is recommend to prevent damage or head securely into the shock cylinder marks to the shock It is important that the gas shock 12 Pressurize the shock through the pressure valve be retained in the vice by the lower mount Any other with nitrogen gas to the specified pressure method of securing the shock body during these 13 If using RydeFX inflation tool Refer to Procedures for procedures may deform the shock body cylinder use of replaceable inflation needle instruction manual NOTE The next points on IFP are not applicable for found in the RydeFX inflation tool case emulsion shocks Proceed to assembly of the 14 After being compressed the piston rod should fully pressure valve extend from the shock body once the shock has been TA pressurized 3 2 22 2 15 Install the small button head screw the pressure valve assembly and tighten securely appropriate measurement Depending on which shock absorber is being worked on adjust the piston 16 Reinstall sleeve and bushings in lower shock mount location tool to the specified depth indicated in the sho
30. bly 1 Remove the bushings and eyelet components from the lower shock body Mount the shock in a soft jawed bench vise 14 Fillthe shock body with oil to the bottom of the threads 2 Remove the button head screw from the pressure Carefully insert the piston rod and valve assembly into valve assembly the cylinder Slightly oscillate the piston rod to allow the piston to enter the shock body bore as it purges the air out Slight up and down movement may be required to allow all the air to pass through the piston assembly 15 Slowly push the piston rod and assembly into the shock body until the threads can be engaged NOTE During installation some shock oil will over flow Wrap a shop cloths around the shock body to catch any oil overflow IMPORTANT Fast installation of the piston rod and assembly may displace the internal floating piston TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual C POLARIS 2010 Polaris Sales Inc 9 36 3 Slowly open the pressure valve assembly Allow all of the nitrogen gas to escape from the reservoir and shock assembly 4 When all of the gas has escaped the reservoir carefully push the reservoir cap down to expose the c clip Using a pick remove the c clip from the reservoir body 5 Remove the cap from the reservoir body 6 Using an adjustable wrench slowly remove the shock rod bearing cap from the shock body 7 Using a 1 8 Allen Wrench
31. cation SHOCK ROD GAS FILL PORT 7 B SHOCK BODY GAS FILL NES Air 2 0 Shock Notes All shock work must be performed when the shock assembly and nitrogen supply tank are at least 70 F 21 C Nitrogen pressure changes by approximately 2 for every 10 F from 70 F Polaris calibrates all shocks at 30 F ride temperature Any IFS shock service that requires gas recharging needs to be performed on both IFS shocks to maintain the same spring rate between both shocks When charging any shock let the nitrogen gas stabilize within the shock for at least 30 seconds before removing the shock charge needle from the charge port 9 26 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc If the rider is requesting stiffer shock settings for more bottoming resistance increase the shock rod nitrogen pressure in 5 PSI increments until the desired performance level is achieved Do not exceed 200 psi shock rod chamber pressure Always reset the shock body chamber pressure to the factory specification charge If the rider is requesting softer shock settings for less bottoming resistance decrease the shock rod nitrogen pressure in 5 PSI increments until the desired performance level is achieved Again always reset the shock body chamber pressure to the factory specification charge If one shock appears to be too soft place the vehicle on flat level ground Stand on the sled
32. ck specification chart 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 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 Screw the pressure valve assembly into the valve port by hand with a slotted head screwdriver and tighten to 100 110 in Ib of torque 7 Fill the shock body with shock oil Internal Floating Piston Shocks Fill the shock body with shock oil to the bottom of the thread within the cylinder Emulsion Shocks Fill shock body with 110cc s of oil This will allow for the required air space to properly gas charge the shock with nitrogen gas NOTE After filling the shock body with oil allow a couple of minutes for all air bubbles to rise to the top POLARIS QUERY Qe M di Shocks FOX PS 5 DISASSEMBLY 1 2 3 Remove the shock from the vehicle Remove the steel sleeve from the eyelet using the mallet and an appropriate sized socket Pry the polyurethane bushings out using the flat blade screwdriver being careful not to scratch the body cap Clean the entire shock assembly with soapy water Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush Never
33. clean shop towel around the service port and then insert the needle of the charge tool into the shock body service port for at least 30 seconds to release all of the nitrogen gas Perform this step with the reservoir service port if required 9 32 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 6 Turn the reservoir adjuster cap to the full soft position all 8 lines visible 7 Remove the seal head from the shock body with a large adjustable wrench Extract the shock rod assembly from the shock body Remove the shock from the vise and pour the oil into an appropriate container Remove the shock body service port 9 When servicing the reservoir remove the adjuster service port Turn the adjuster cap counterclockwise until the cap comes off the reservoir body 10 Remove the snap ring Carefully extract the adjuster piston from the reservoir Discard the o ring and replace with new 11 Point the reservoir body down while holding a hand towel over the open end Insert an air chuck into the shock body service port and blow the IFP out of the reservoir 12 Discard the wearband and o ring Replace with new parts 13 Remove the bolt securing the piston assembly to the shock rod Remove the valve shims and place them on a paper towel or shop rag in the order in which they are removed 14 Remove the washers and droop plates from the rod Carefully pull the seal head off of the shock rod 15 In
34. d into the 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 the piston assembly 9 30 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 19 Using interlocking channel pliers securely tighten the cylinder head on the shock body 20 Pressurize the shock body cylinder with nitrogen gas to specification 21 Install the small button head screws back into each valve assembly 22 Reinstall the eyelet hardware and test shock After being compressed the piston rod must fully extend from the body TERRAIN DOMINATION POLARIS Shocks Walker Evans Air Shock Disassembly IMPORTANT Verify the protective outer boot is not torn or damaged If damaged inspect the shock shaft for damage Replace shock shaft if damage is found BODY CAP _ SERVICE PORT 1 j BUTTON HEAD SCREW SHOCK md RETAINING BOLT REBOUND VALVE STACK COMPRESSION VALVE STACK le U CUP SEAL 4 SEAL HEAD T RJ d WIPER SEAL SHOCK ROD ROD BEARING CAP 1 Place the body cap of the shock in the vise so that the shock rod is facing downward 2 Remove the service port screw and release the pressure with the shock charging needle Verify all pressure is released 3 Place the body cap in the vise with the shock rod facing upward 4 Slowly loose
35. ed edges or excessive wear O rings for nicks cuts or cracks Valve discs for kinks or waves 9 28 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Ryde FX Air 2 0 Shock Assembly 1 Place the 36mm piston rod upper mount soft jawed bench vise Lubricate the internal IFP and o ring with shock oil 2 Install the internal IFP flat side o ring side first into the piston rod 3 Install the rod head assembly Torque to specification ey T Rod Head Bolt Torque 50 Ft Lbs 68Nm 4 Install the compression and rebound valve shim stacks back on to the piston valve assembly in the order they were removed Apply a small amount of Loctite 290 to the bolt threads Thread piston assembly into piston rod by hand 6 Torque bolt to specification ey T Piston Valve Bolt Torque 28 32 Ft Lbs CAUTION DO NOT OVER TORQUE PISTON VALVE BOLT TERRAIN DOMINATION POLARIS Shocks 7 Apply alight film of grease to the 36mm rod assembly pressure valve port counter bore where the pressure valve assembly o ring meets 8 Install pressure valve assembly and torque to specification Pressure Valve Assembly Torque 100 110 In Lbs 9 Pressurize the 36mm piston rod through the pressure valve with nitrogen gas to the specified pressure NOTE The internal IFP will be forced to the top of the piston rod after cylinde
36. equire changing the valve stack TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Walker Evans IFS Air Remote Reservoir Piggyback Shock NOTE When servicing any air IFS shock recharge both shocks to the same pressure setting Raise the vehicle off the ground or remove shocks completely Discharge the shock gas pressure completely before refilling the shock with nitrogen Perform work on shocks when shocks and nitrogen gas supply tank are at room temperature 70 F 21 C The wrench tool PN 5136694 is used to adjust the reservoir adjuster piston setting The tool is supplied in the vehicle tool kit Walker Evans NOTE Using another tool to turn the adjuster cap may damage the shock Turn the cap clockwise for a stiffer ride Turn the cap counter clockwise for a softer ride Full soft is when 8 lines are visible Each line represents approximately 40lbs of spring rate at the mid stroke Make changes in small increments 2 lines maximum 9 25 Shocks Ryde FX Air 2 0 Shock The shock rod pressure setting can be adjusted to accommodate different rider weights and riding styles Before making any shock pressure adjustments the rider should ride the snowmobile for at least 250 500 miles in all types of riding conditions NOTE Do not adjust the shock body chamber pressure setting Always charge the shock body chamber to specifi
37. f o ring use the non writing end of a pen or a similar soft blunt object to push it in 6 Installthe new welllubricated o rings into the bearing housing Correct placement of the shaft seal o ring is in the groove next to the DU bushing Check to make sure the seals are properly seated and are not twisted If a tool is required to aid in proper seating of o ring use the non writing end of a pen or a similar soft blunt object to push it in 7 Install the new u cup seal into bearing U cup should be installed so the cupped end is facing the DU bushing inside of bearing Check to make sure seal is properly seated If a tool is required to aid in proper seating of U cup seal use the non writing end of a pen or a similar soft blunt object to push it in 8 Install FIST bearing into housing Check for proper orientation of the FIST bearing The stepped side of the FIST bearing should be visible 9 Usingasmall pair of snap ring pliers install the snap ring into the bearing housing Check for proper orientation of the snap ring The flat side of the snap ring should be visible Check to make sure the snap ring is properly seated 10 Install the new well greased o ring onto the IFP 11 Install a new o ring on the IFP bleed screw TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 9 43 Shocks NOTES TERRAIN DOMINATI 9922854 2007 2011 IQ Service
38. gainst the c clip 17 Charge the reservoir with nitrogen to the specified pressure Once pressurized the shock rod should fully extend 18 With pressure working against the reservoir cap secure the pressure valve into the cap then remove the shock fill tool from the valve Reinstall the button head screw TERRAIN DOMINATION 4 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 9 39 Shocks RYDE FX MONO TUBE SHOCK DISASSEMBLY Procedures for the proper disassembly and assembly of Ryde FX gas charged IFP and emulsion mono tube shock absorbers CAUTION BEFORE SERVICING A GAS SHOCK IT IS IMPORTANT THAT ALL THE GAS PRESSURE BE DISCHARGED FROM THE UNIT REFER TO THE INSTRUCTIONS LISTED BELOW FOR THE PROPER PROCEDURE OF DISCHARGING THE GAS PRESSURE FROM A SHOCK PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY WHILE SERVICING RYDEFX GAS CHARGED MONO TUBE SHOCKS Remove the shock s from the vehicle 2 Before unscrewing pre load springs measure the compressed length of the installed spring and mark position for reinstallation 3 Ifthe shock incorporates a spring remove the spring and all collateral retainers CAUTION When removing the spring from a shock that utilizes a fixed lower retainer the use of a proper spring compressor should be used to avoid risk of bodily injury 4 Wash the shock body in parts cleaner then dr
39. hen shock rod is locked in a table vise eyelet down threaded end up TERRAIN DOMINATION 9 11 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS Shocks 2008 Shock Specifications 2008 Front Suspesion Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH STROKE OIL PSI IN IN VOLUME IN IN IN 7043245 Ryde FX 17 98 11 77 6 21 49 6 92 Full 200 Ryde FX 36mm Rod Cylinder 145 PSI 7043315 20 18 00 11 80 6 20 N A 5 75 Full 47mm Body Cylinder 60 PSI Walker 7043364 7043490 17 02 11 27 5 75 1 124 95 220 NOTE Original subs to number Reference new PN s specifications when servicing 2008 Front Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH gue mi OiL VOLUME PSI IN IN IN 7043244 Ryde FX 12 12 8 61 3 52 50 4 68 Full 200 7043365 12 49 8 92 3 57 1 124 60cc 217 5 2008 Rear Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH ira IFE M OiL VOLUME PSI IN IN IN 7043177 Fox 15 60 10 56 5 04 50 1 22 Full 200 7043216 Fox 14 12 9 29 4 83 50 2 40 Full 300 7043316 Ryde FX 15 60 10 60 5 00 50 1 60 Full 200 7043366 Walker Evans 16 71 10 96 5 75 50 6 75 Full 200 9 12 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales
40. inspect or replace Inside of shock body for scratches burrs or excessive wear Teflon piston and LF P wear band for cuts chipped or nicked edges or TERRAIN DOMINATION POLARIS Shocks excessive wear O rings for nicks cuts orcracks Cap 8 With the cylinder head assembly pushed down and rod seals for nicks cuts or cracks Valve discs for against the piston carefully insert the piston rod and kinks or waves Compression bumpers ski shocks assembly into the cylinder Slightly oscillating the only for chipping cracking or missing Should any of piston rod to allow piston to enter shock body bore A these items be question replacement is light coating of oil on the piston wear band will ease recommended installation 9 Slowly push the piston rod and assembly into shock RYDE FX MONO TUBE SHOCK ASSEMBLY body until the cylinder head assembly bottoms on the 1 Place the piston rod upper mount into the vise DE Slight up our mble damper rod assembly in the reverse may be required to allow all air to pass through piston order of disassembly Special attention should be 258300 1 paid the order of the Rebound and Compression disc 10 During installation some shock oil will overflow Wrap shim stacks ensuring that they are in the same a shop cloth around SHOCK body to order prior to disassembly Tighten the lock nut to 15 overflow Fast Sta aH pr ine piston rod 20 ftl
41. ld shock oil Using the handle of the mallet push the IFP out of the shock body on to a folded shop towel Remove the bleed screw from the IFP using the 1 8 T Handle Clean the IFP with solvent Dry with compressed air in a well ventilated area If compressed air is not available dry parts using clean lint free paper towels 17 18 19 20 21 22 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc and let sit in a well ventilated area to allow the solvents to evaporate Set body assembly aside on a clean lint free towel Clamp the shaft eyelet securely in vice with the piston end up Using a 9 16 wrench remove the piston lock nut from the end of the shaft Hold the tip of the Phillips Head Screwdriver against the end of shaft Hold the piston assembly under the top out plate and lift upwards Slide the piston assembly onto the shaft of the screwdriver Pull the Screwdriver away from shock shaft while supporting the piston assembly Set this on a clean lint free towel There are many pieces to the piston assembly and the assembly order of these pieces is critical to the proper performance of your shock This step ensures that the proper order is kept Slide bearing assembly off of shaft Use extreme caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft and set it on a clean lint free towel Remove the bleed screw from the IFP and
42. low the oil to absorb the nitrogen gas IMPORTANT Never re insert the fill tool needle back into the shock to check pressure after initial charging The amount of gas required to fill the tool will give a false pressure reading Always completely discharge the shock and refill to obtain an accurate pressure reading 18 Check for any leaks 19 Reinstall the protective boot and carefully reinstall shock 9 33 Shocks Walker Evans Remote Reservoir Piggyback Shock Disassembly NOTE Remote reservoir shock shown IMPORTANT To prevent damage or marks to the shock the use of soft jaws on a vise is recommended remove shock from the 1 Clean and carefully suspension 2 Remove button head screw from reservoir cap if applicable shock 4 Press the end cap into the reservoir to access the snap ring 5 Remove the snap ring then remove the cap from the body 9 34 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 6 Place the shock lower eyelet in a vise 7 Loosen and remove the bearing cap from the shock 8 Remove the used oil from the shock body NOTE Insert the IFP tool PN PS 45908 and cycle the internal floating piston IFP a few times to purge the shock oil from the reservoir 9 Remove the IFP from the reservoir with the IFP tool PN PS 45908 10 Clean and inspect ALL parts and replace worn out parts if needed IMPORTANT Seal kits are available and
43. n a soft jawed bench vise Fill the shock body with new Ryde FX shock oil Fill until the level of the oil is one inch below the top of the reservoir body 6 Using a Vernier Caliper set the caliper leg to the specified IFP locating position for the shock 7 Apply a thin layer of shock oil to the IFP o ring and wear band 8 Carefully install the IFP back into the reservoir Setthe IFP to the specified depth Take care not to damage 9 38 10 11 the IFP wear band while setting the IFP depth Whenthe IFP is setto the depth specification reinstall the bleed screw Fill the shock body with new Ryde FX shock oil to the bottom of the shock body threads Carefully and slowly install the shock rod bearing assembly back into the shock body Use a slight up and down movement to dispose of any air trapped below the piston assembly 12 13 14 15 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Using an adjustable wrench secure the bearing cap assembly to the shock bogy Pour all of the remaining oil out of the reservoir body into a suitable container Apply a light film of Lithium grease to the pressure valve counter bore on the reservoir cap Apply a thin layer of shock oil to the cap o ring then carefully reinstall the cap back into the reservoir Push cap just below the c clip groove TERRAIN DOMINATION POLARIS Shocks 16 Use a pliers to pull the cap up a
44. n the seal head and remove 5 Empty all the shock oil from the shock body and discard 6 Inspectthe valve stack as needed Replace any worn wavy or bent valve shims TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 7 l fvalve shim service or adjustment is done torque the piston retaining bolt to specification ey T Piston Retaining Bolt 25 30 ft lb 34 41 Nm 8 Replace the wiper seal u cup seal and o ring with new parts CAUTION Take note of the orientation of the seal head seals Use a soft faced tool like a pen or similar object to install the o ring and seals Walker Evans Air Shock Assembly 1 Place the specified amount of fluid into the shock body CAUTION Do not overfill the shock oil level Too much shock oil may cause the shock rod to hydrolock 2 Install the seal specification 6 1 Seal Head Assembly Torque 25 35 ft lb 34 47 Nm DO NOT OVER TORQUE head assembly Torque to 3 Pressurize the shock to specification Hold the fill tool needle in the port for at least thirty seconds to allow the oil to absorb the nitrogen gas IMPORTANT Never re insert the fill tool needle back into the shock to check pressure after initial charging The amount of gas required to fill the tool will give a false pressure reading Always completely discharge the shock and refill to ob
45. ng wear band located on the shock rod piston Compress the wear band and insert the IFP into the reservoir Allow as much air as possible to escape as you install the piston Screw the IFP tool PN 5 45908 into the IFP Hold or place the reservoir as low as possible so the air will travel upward as you slowly cycle the IFP up and down Be sure to bottom out the piston in the reservoir body Allow time for the bubbles to dissipate Repeat the process until all the air has been removed 9 35 Shocks 12 Set the IFP so it is approximately 1 8 from the bottom IFP from its original position Performance issues of the reservoir Install the bleed screw will be a result if the IFP is not in its specified position 16 Tighten the cylinder head onto the shock bogy 17 Verify the IFP is set at the specified depth If not verify there is oil on top of the IFP then open the bleed Screw 18 Set the IFP to specification then close the bleed Screw 19 Pour out any remaining shock oil from the reservoir 20 Install the cap making sure the o ring does not flip over Install the snap ring 21 Charge the shock to the specified pressure 22 Clean the shock of all oil reside and check for any leaks 23 Install button screw onto the reservoir cap 13 With the cylinder head assembly pushed down against the valve piston dip the piston assembly Ryde FX Remote Reservoir Shock shock oil Disassem
46. ower shock body mount eyelet components Secure shock in a soft jawed table vise 6 Using interlocking channel pliers loosen and remove the cylinder head assembly 3 Remove both small bottom head screws form each pressure valve assemblies located at both ends of the shock 7 Pour the oil out of the cylinder Discard oil into an approved container and dispose appropriately Never reuse shock oil TERRAIN DOMINATION 9 27 4 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc Shocks 8 Using compressed air invert the large diameter cylinder over a clean shop towel Pressurize the cylinder to 90 psi to remove the IFP from the cylinder Account for the floating piston wear band and o ring 9 Place the 36mm piston shock rod upper mount in a soft jawed bench vise Remove the piston valve and valve shim assembly from the rod in the sequence of disassembly Shock Absorber Part 7043315 1 8 rod shaft 11 Again using compressed air invert the rod shaft over a clean shop towel Pressurize the cylinder to 90 psi to remove the IFP from the cylinder Account for the floating piston and o ring 12 With the shock disassembled inspect the following items 36mm piston rod for straightness nicks or burrs Cylinder head assembly bearing Inside of shock body for scratches burs or excessive wear Teflon piston and IFP wear band for cuts chipped or nick
47. r is pressurized 10 Secure the shock body lower mount in a soft jawed 11 Thread the head onto the IFP locator tool and adjust the top of the value indicator to the specified IFP measurement 12 Apply a thin layer of oil to the IFP wearband and o ring Insert the IFP o ring side first into the shock body 13 using the IFP locator tool slowly push the IFP down into the cylinder The IFP is set to the correct position when the indicator knob makes contact with the shock body 9 29 bench vise 14 Install the pressure valve assembly into the valve port and torque to specification T Pressure Valve Assembly Torque 100 110 In Lbs POLARIS Gars Shocks 15 Slowly fill the shock body with Ryde FX shock oil up to the level of the outer threads NOTE Allow the shock to stabilize for several minutes and allow the air bubbles to escape to the top Wrap the shock body with clean shop towels to catch any shock oil spillage 16 Invert the 36mm piston rod assembly and pour a small amount of shock oil into the center of the locking piston bolt until the oil flows back out of the hole 17 Hold a finger over the bolt hole then carefully insert the piston rod into the shock body cylinder Slightly oscillate the piston rod to allow the piston to enter the shock body bore ens 7 Wi 18 Slowly push the piston ro
48. set them both on a clean lint free towel TERRAIN DOMINATION POLARIS Shocks FOX PS 5 ASSEMBLY 1 Using a small pair of snap ring pliers remove the snap ring from the bearing housing Using your fingers remove the FIST scraper from the housing Use a scribe or a dental pick to remove the o ring from the inside of the FIST scraper by spearing the seal with the point of the scribe and pulling it out Use extreme caution when using a scribe to remove seals Always spear the seal with the point of the scribe Do not wedge the point of the scribe in behind the seal This can scratch the surface of the seal groove which will compromise the performance and reliability of the shock absorber 2 Use the scribe to remove the u cup wiper and o ring seals from the bearing housing Be careful not to scratch the seal grooves or the DU bushing that is pressed into the bearing 3 Thoroughly clean the FIST scraper bearing housing and piston assembly with solvent Dry with compressed air in a well ventilated area If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate 4 Use a scribe or dental pick to remove the o ring seal from the IFP 5 Install the new well lubricated o ring into the FIST scraper Check to make sure the seal is properly seated and is not twisted If a tool is required to aid in proper seating o
49. spect the washers and shims for any damage or warping Replace parts as required Replace the piston valve wearband 16 Replace the seal head o ring u cup seal and wiper seal with new parts Apply a thin coat of grease to the o ring and seals to aid assembly CAUTION Take note of the orientation of the seal head seals Use a soft faced tool like a pen or similar object to install the o ring and seals NOTE The split bushing pressed into the seal head is not serviceable TERRAIN DOMINATION POLARIS Shocks Walker Evans Air Piggyback Shock Assembly 1 If the reservoir has been disassembled begin the assembly process by assembling the reservoir 2 Install the reservoir with the o ring down and wear band up into the reservoir Push the IFP down until it bottoms out in the reservoir 3 Lubricate the adjuster piston s o ring with shock oil and then install into reservoir just below the snap ring groove 4 Install the snap ring and then pull the adjuster piston up against the ring 5 Screw the adjuster cap on to the reservoir until it seats against the adjuster piston Install the service port Hand tighten the service port into the adjuster piston NOTE Do not over torque the service port into the adjuster piston 6 Turnthe adjuster cap to the full soft position all 8 lines showing on reservoir body 7 Charge the reservoir with nitrogen gas to the specified pressure 8 In
50. stall the button head screw into the service port 9 Install the service port into the shock body 10 Fill the shock body with the specified amount of Walker Evans 5W Shock Oil CAUTION Do not overfill the shock oil level Too much shock oil may cause the shock rod to hydrolock 11 Gently rotate the shock body to release as much trapped air as possible NOTE A small a amount of air will always be present when adding shock oil due to the design of the shock This isn t a problem because the shock is an emulsion design where the gas and oil are mixed 12 Reinstall the shock rod valve stack Verify the valve stacks are installed as they were removed Torque the valve stack bolt to specification ey T Valve Stack Bolt Torque 25 30 Ft Lbs 34 41 Nm 13 Carefully install the shock rod into the shock body Install slowly to reduce oil loss and to prevent oil foaming 14 Slowly stroke the piston valve stack up and down under the top level of the oil TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 15 Screw the bearing head on to the shock body torque to specification 6 1 Bearing Head Torque 25 35 Ft Lbs 34 47 Nm 16 Screw the bearing head on to the shock body torque to specification 17 Pressurize the shock to specification Hold the fill tool needle in the port for at least thirty seconds to al
51. tain an accurate pressure reading 4 Checkfor any leaks 5 Reinstall the protective boot and carefully reinstall shock 9 31 Shocks Walker Evans Air Piggyback Shock Disassembly IMPORTANT Verify the protective outer boot is not torn or damaged If damaged inspect the shock shaft for damage Replace shock shaft if damage is found NEEDLE VALVE O RING BUTTON HEAD SCREW SHOCK BODY BODY LOOR gt RS IFP Des eat 4 WNEARBAND RESERVOIR BODY ADJUSTER PISTON IF Z O RING H 5 SNAP RING BOLT ni n 4 NEEDLE VALVE f O RING BODY k BUTTON HEAD SCREW PEAL HEAD UE aN RESERVOIR O RING E LI WEARBAND U CUP 7 DROOP PLATE ASM WIPER SEA HT HAT SHOCK ROD 4 WALKER EVANS IFS AIR PIGGYBACK NOTE The reservoir can remain charged and left alone if the technician only desires changing the shock oil and or servicing the rod piston valve stack seal head assembly 1 Install the foam sleeve on the shock shaft and remove from the vehicle Clean the shock 2 Inspectthe shock rod The rod will have to be replaced if there are nicks or gouges in the shaft surface 3 Secure the body loop in a bench vise 4 Remove the button head screws from the shock body service port You only have to depressurize the reservoir chamber if reservoir service is required 5 Wrap a
52. x 15 60 10 56 5 04 50 1 22 Full 200 7043246 Fox 16 60 10 91 5 96 50 2 23 Full 200 7043266 Fox 15 65 10 56 5 09 50 1 63 Full 200 7043205 Walker Evans 15 60 10 56 5 04 625 2 25 Full 200 7043216 Fox 14 12 9 29 4 83 50 2 40 Full 300 7043235 Walker Evans 16 71 10 96 5 75 50 7 25 Full 200 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS Shocks 2007 Shock Valve Shim Stack Configurations NOTE All measurements in inches 2007 Front Suspension Shocks 7043268 7043233 7043233 SHOCK 7042258 7043141 7043095 7043090 7043082 7043206 7043269 Stock Optional 625 065 700 010 620 093 620 093 625 x 065 625 x 065 700 x 010 800 x 010 a 700x 008 700x 012 700x 015 700 x 008 2 700 x 010 800 x 010 700 x 010 800 010 900x 010 800 x 008 800x 012 800x 015 800 x 008 5 800 x 010 900 x 010 800 x 010 900 010 1 000x 010 900 008 900 012 900x 012 900 x 008 nd Re ee lee el 900 x 010 1 00x 010 1 100x 010 2 005010 1 00 x 010 110x 012 1100 x 015 1100 x008 sees come lll 1 100 aoe 250x 006 1 10 x 008 140x 010 1 200x 015 oc 250 1 20 x 008 120x 012 1 250 x 015 250 x 250 x 120x 010 1 250 x 015 Piston 052 Orifice 060 078 078 052 081 093 052 052 1 300 x 015 1 30 x 006 1 30 x 006 1 30 x 015 z 1 300 x 008 1
53. y with compressed air to remove sand and dirt A WARNING WHEN USING COMPRESSED AIR TO DRY COMPONENTS PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY 5 Remove bearing sleeve and or bushings from lower shock mount eyelet Secure the lower mount of the shock in a vise The use of soft jaws is recommend to prevent damage or marks to the shock CAUTION It is important that the gas shock be retained in the vise by the lower mount Any other method of securing the chock body during these procedures may deform the shock body cylinder 6 Remove the small button head screw from the pressure valve assembly 9 40 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 7 Depressurize the shock NITROGEN GAS IS UNDER EXTREME PRESSURE USE A WARNING CAUTION WHEN RELEASING NITROGEN GAS FROM SHOCK PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY 10 11 12 13 14 15 16 17 Internal Floating Piston Shocks using slotted screwdriver loosen the pressure valve assembly counter clockwise two full revolutions allowing the gas pressure to fully escape past the pressure valve assembly O ring Emulsion Shocks With the shock inverted and the piston rod fully extended secure the lower mount of the shock in a vise Allow a couple of minutes for the gas pressure to separate from the oil and rise to the top Using a rag as a shield
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