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BODY / STEERING / SUSPENSION
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
12. Fill shock body to the bottom of bearing threads with oil.
13. Using the IFP Depth Setting Tool, slowly pull the IFP up
to the mid point of the reservoir. Then push it down to the
bottom again (Fig. 14). Be careful not to pull the IFP out
completely. Also, be careful that the oil level in the shock
body does not disappear below the bottom of the body and
into the reservoir. If the oil does recede completely from the
body, you must remove the IFP and go back to step 7 of
reassembly.
14. As you push the IFP down, you should see bubbles rising
to the surface inside the body tube. Repeat this process
several times until you don’t see any new bubbles inside the
body tube.
15. Pull the IFP up until it’s top is approximately 1” from the
end of the reservoir and remove the IFP depth setting tool.
Again, be sure the oil level in the shock body does not drop
below the bottom of the body. If the oil does recede
completely from the body, you must remove the IFP and go
back to step 7 of reassembly. Add oil if necessary while
pulling up on the IFP.
16. Using the flat blade screwdriver, turn the Compression
Adjuster Screw clockwise until it stops turning.
17. Fill the body tube with oil approximately 1/4” below the
threads. Wrap the new piston band around the piston,
making sure the rounded edges face out. Insert the shaft
assembly into the body tube. Slowly push shaft into body
until piston assembly is approximately 1” below oil surface.
18. Stroke the shaft up and down slowly over about a 1” range
until no air bubble rise from the damping piston. Be careful
to keep the damping piston at least 1/4” below the surface
of the oil during this process.
19. Bring the damping piston up until it is approximately 1/4”
below the surface of the oil. Using the mallet, give 2 - 3
sharp blows to the eyelet, driving the damping piston down
into the shock body. This opens the valves on the damping
piston. You will see the released air bubbles come to the
surface of the oil.
20. Add oil to the body tube until the surface of the oil is to the
top of the threads inside the body tube.
21. Pull the damping piston up until it is just below the surface
of the oil. Add more oil if necessary.
22. Hold the shaft eyelet with one hand. With other hand, slide
the bearing assembly down the shaft until contact with the
body is made. Oil will overflow from around the bearing
(Figure 16).
23. Screw the bearing assembly into the body tube by hand,
holding the shaft up so that the bearing is in contact with
the bottom of the damping piston assembly. Be careful not
to cross-thread the bearing assembly. When the bearing will
no longer thread in by hand, turn the Compression Adjuster
Screw all the way counter clockwise using the flat blade
screwdriver.
24. Tighten the bearing assembly using the appropriate size
open end wrench.
25. Set IFP depth tool to specified length for the correct IFP
depth.
26. Insert IFP depth setting tool into reservoir and engage IFP.
Using a long 1/8” hex tool, remove the bleed screw from
the center of the IFP. TIP: Apply grease to the end of the
hex tool so that the bleed screw sticks to it. This will make
it easier to remove it from the IFP.
27. Push the IFP down to the correct depth setting. As you do
this, keep the open end of the IFP depth setting tool covered
with your hand. Oil will stream through the bleed hole in
the IFP as you push it further into the reservoir (Fig. 17).
Figure 14
Shock IFP Depth:
Front: 2.40” (6.10 cm)
Rear: 3.40” (8.64 cm)
Figure 16