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5.51
BODY / STEERING / SUSPENSION
5
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
7. Install the scraper in the bearing housing. Check for proper
orientation of the scraper in the bearing. The stepped side
of the scraper should be visible.
8. Install the new, well greased O-ring onto the IFP.
9. Replace the IFP bleed screw O-ring.
10. Install the new, well greased O-rings into the reservoir end
cap.
FOX™ Shock Reassembly
1. Clamp shaft eyelet securely in vise, and place seal bullet
tool on end of shaft.
2. Lubricate the bearing assembly seals with an ample amount
of assembly lube. Slide the bearing assembly onto shaft
with the scraper facing the eyelet (Fig. 11). This should be
done in a single smooth motion to avoid damaging the seals.
3. Insert the shaft of a Phillips head screwdriver through the
center of the piston assembly. The pointed end of the
screwdriver should be on the same side as the top-out plate.
Cut and remove the tie wrap that was holding the piston
assembly together.
4. Hold the piston assembly from underneath the top-out plate
and place the end of the screwdriver onto the end of the
shock shaft. Slide the piston assembly onto the shaft end.
Check to make sure the piston assembly is properly seated,
then install the piston lock nut. Torque the nut to 18 ft. lbs.
(24 Nm) using a torque wrench and 9/16” socket. Remove
shaft assembly from vise and set it aside on a clean, lint free
paper towel.
5. Clamp the body cap of the shock securely in the vise, with
the open end of the body facing up.
6. Using the flat blade screwdriver, turn the compression
adjuster screw counter clockwise until it stops turning.
7. Lubricate the new IFP O-ring with an ample amount of
assembly lube.
8. Fill the reservoir to the retaining ring groove with the
recommended oil. You should see bubbles rising to oil
surface. Wait until bubbling slows or stops completely. If
oil level has fallen, add more oil until level is at retaining
ring groove. Insert IFP into reservoir. Use a smooth motion
and push straight in until O-ring seats into the retaining ring
groove. Use your free hand to wrap new piston band around
IFP with the rounded edge out, and push the IFP into the
reservoir. Shock oil will come up through the IFP bleed
hole.
9. Push the IFP into the reservoir until you have enough oil
on top of the IFP so that the bleed hole is under the surface
of the oil (Fig. 12).
10. Quickly install the IFP Bleed Screw before the oil level
drops and tighten it with the 1/8” Hex Tool (Fig. 13).
NOTE: The IFP will spin in the reservoir when the
screw bottoms. This is OK.
11. Using the IFP Depth Setting Tool, push the IFP into the
reservoir until it stops.
Figure 11
Polaris Gas Shock Oil - 5 wt.
PN 2870995 - qt.
PN 2872279 - 2.5 gal.
Figure 12
Figure 13