Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 57

 

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Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 57

 

 

10.29

Rear Suspension

10

Rev. 1 07/2006

SPECIAL TOOLS

Shock Rebuilding Tools

Special Tools

PART NUMBER

DESCRIPTION

2200421

Gas Shock Recharging Kit

2201639

Shock Shaft Seal Protector 1/2” Diameter

2201640

Shock Shaft Seal Protector 5/8” Diameter

2870623

Shock Absorber Spring Compression Tool

2870803

Shock Spring Pre-Load Adjustment Too

PS-45259

Gas Fill Tool

9917736 

VIDEO-Rebuilding Mono Tube Shocks

9917737

VIDEO-Rebuilding Remote Reservoir Shocks

Ryde FX Shock Special Tools

PART NUMBER

DESCRIPTION

PS-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 1/2" rod

2872429

Shock Rod Holding Tool 5/8" rod

2871232

Fox Shock Spanner

2871351

Fox Shock IFP Depth Tool

PS-44925

Fox Inner Tube Puller PS 2

10.30

Rear Suspension

Rev. 1 07/2006

SHOCK MAINTENANCE

SHOCK MAINTENANCE

It is recommended to change the shock oil annually and should
be included when performing end of season storage preparation.
Changing the shock oil will prevent internal corrosion and
moisture absorption.

When performing maintenance, use Gas Shock Recharging Kit,
PN 2200421. The kit consists of the necessary valves, pressure
gauge, and fittings to deflate and pressurize the shocks. The
Body Holder Tool, Internal Floating Piston (IFP), and Shock
Rod Holding Tool are not included in the Recharging Kit and
must be ordered separately. Refer to the SPX Specialty Tool
catalog for part numbers.Videos on shock rebuilding are also
available. Monotube shocks 9917736, Remote Reservoir
9917737. 

RYDE FX MONO-TUBE SHOCK 

DISASSEMBLY

Procedures for the proper disassembly and assembly of RydeFX
gas charged IFP and emulsion mono-tube shock absorbers.

1.

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.

If the shock incorporates a spring, remove the spring and
all collateral retainers.

4.

Wash the shock body in parts cleaner; then dry with
compressed air to remove sand and dirt.

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.

6.

Remove the small button head screw from the pressure
valve assembly.

7.

Depressurize the shock with the charging needle.

8.

Internal Floating Piston Shocks: Using a slotted
screwdriver, loosen the pressure valve assembly counter-
clockwise two full revolutions allowing any residual gas
pressure to fully escape past the pressure valve assembly O-
ring.

9.

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 to prevent spraying of gas and oil, depressurize the
shock with the shock charging needle. Then, loosen the

CAUTION

E

XTREME

 

CAUTION

 

SHOULD

 

BE

 

OBSERVED

 

WHILE

 

HANDLING

 

AND

 

WORKING

 

WITH

 

HIGH

 

PRESSURE

 

SERVICE

 

EQUIPMENT

W

EAR

 

A

 

FACE

 

SHIELD

SAFETY

 

GLASSES

AND

 

EAR

 

PROTEC

-

TION

 

DURING

 

SERVICE

 

OF

 

THESE

 

SHOCKS

. C

ARE

 

SHOULD

 

BE

 

OBSERVED

 

WHILE

 

HANDLING

 

THE

 

INFLATER

 

NEEDLE

 

AND

 

PRESSURE

 

GAUGES

. M

AINTAIN

 

YOUR

 

EQUIPMENT

 

AND

 

KEEP

 

IT

 

IN

 

GOOD

 

WORKING

 

CONDITION

. I

F

 

INJURY

 

SHOULD

 

OCCUR

CONSULT

 

A

 

PHYSICIAN

 

IMMEDIATELY

. E

XTREME

 

CLEANLI

-

NESS

 

IS

 

OF

 

UTMOST

 

IMPORTANCE

 

DURING

 

ALL

 

DISASSEMBLY

 

AND

 

REASSEMBLY

 

OPERATIONS

 

TO

 

PREVENT

 

ANY

 

DIRT

 

OR

 

FOREIGN

 

PARTICLES

 

FROM

 

GETTING

 

INTO

 

THE

 

SHOCKS

K

EEP

 

THE

 

PARTS

 

IN

 

ORDER

 

AS

 

THEY

 

ARE

 

DISASSEMBLED

N

OTE

 

THE

 

DIRECTION

 

AND

 

POSITION

 

OF

 

ALL

 

INTERNAL

 

PARTS

 

FOR

 

REASSEMBLY

.

CAUTION

B

EFORE

 

SERVICING

 

A

 

GAS

 

SHOCK

 

IT

 

IS

 

IMPORTANT

 

THAT

 

ALL

 

THE

 

GAS

 

PRESSURE

 

BE

 

DISCHARGED

 

FROM

 

THE

 

UNIT

R

EFER

 

TO

 

THE

 

INSTRUCTIONS

 

LISTED

 

BELOW

 

FOR

 

THE

 

PROPER

 

PROCEDURE

 

OF

 

DISCHARGING

 

THE

 

GAS

 

PRES

-

SURE

 

FROM

 

A

 

SHOCK

. P

ROTECTIVE

 

EYE

 

WEAR

 

SHOULD

 

BE

 

WORN

 

TO

 

AVOID

 

RISK

 

OF

 

INJURY

 

WHILE

 

SERVICING

 R

Y

-

DE

FX 

GAS

 

CHARGED

 

MONO

-

TUBE

 

SHOCKS

.

CAUTION

W

HEN

 

REMOVING

 

THE

 

SPRING

 

FROM

 

A

 

SHOCK

 

THAT

 

UTILIZ

-

ES

 

A

 

FIXED

 

LOWER

 

RETAINER

THE

 

USE

 

OF

 

A

 

PROPER

 

SPRING

 

COMPRESSOR

 

SHOULD

 

BE

 

USED

 

TO

 

AVOID

 

RISK

 

OF

 

BODILY

 

INJURY

.

WARNING

W

HEN

 

USING

 

COMPRESSED

 

AIR

 

TO

 

DRY

 

COMPONENTS

PROTECTIVE

 

EYE

 

WEAR

 

SHOULD

 

BE

 

WORN

 

TO

 

AVOID

 

RISK

 

OF

 

INJURY

.

CAUTION

I

T

 

IS

 

IMPORTANT

 

THAT

 

THE

 

GAS

 

SHOCK

 

BE

 

RETAINED

 

IN

 

THE

 

VISE

 

BY

 

THE

 

LOWER

 

MOUNT

. A

NY

 

OTHER

 

METHOD

 

OF

 

SECURING

 

THE

 

CHOCK

 

BODY

 

DURING

 

THESE

 

PRO

-

CEDURES

 

MAY

 

DEFORM

 

THE

 

SHOCK

 

BODY

 

CYLINDER

.

WARNING

N

ITROGEN

 

GAS

 

IS

 

UNDER

 

EXTREME

 

PRESSURE

USE

 

CAUTION

 

WHEN

 

RELEASING

 

NITROGEN

 

GAS

 

FROM

 

SHOCK

. P

ROTECTIVE

 

EYE

 

WEAR

 

SHOULD

 

BE

 

WORN

 

TO

 

AVOID

 

RISK

 

OF

 

INJURY

.

10.31

Rear Suspension

10

Rev. 1 07/2006

pressure valve assembly two full revolutions allowing the
any residual gas pressure to escape.

10. 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.

11. Using a slotted screwdriver, remove the pressure valve

assembly from the lower end mount. Account for an O-ring.

12. Using an adjustable face spanner (PN PS45262), fully

loosen and remove cylinder head assembly.

13. 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.

14. Using the I.F.P extraction tool thread the tool into the I.F.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

15. Clean the inside of the shock body using clean parts-

cleaning solvent and blow dry using compressed air.

16. 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).

17. Items to inspect: Piston rod for straightness, nicks or burrs.

Cylinder Head Assembly / DU Bearing clean, inspect, or
replace. Inside of shock body for scratches, burrs or
excessive wear. Teflon piston and I.F.P wear band for cuts,
chipped or nicked edges, or excessive wear. O-rings for
nicks, cuts, or cracks. Cap and rod seals for nicks, cuts or
cracks. Valve discs for kinks or waves. Compression
bumpers (ski shocks only) for chipping, cracking or
missing. Should any of these items be in question
replacement is recommended.

RYDE FX MONO-TUBE SHOCK ASSEMBLY

1.

Place the piston rod upper mount into the vise. Reassemble
damper rod assembly in the reverse order of disassembly.
Special attention should be paid the order of the Rebound
and Compression disc (shim) stacks, ensuring that they are
in the same order prior to disassembly. Tighten the lock
nut to 15-20 ft-lb. of torque. DO NOT OVER-TORQUE.
If excessive torque is applied, damage to the piston and
valves will occur.

2.

Secure the shock body by its lower mount in vise. The use
of soft jaws is recommend to prevent damage or marks to
the shock. It is important that the gas shock be retained in
the vice by the lower mount. Any other method of securing
the shock body during these procedures may deform the
shock body cylinder.

NOTE:  The next points on IFP are not applicable for
emulsion shocks. Proceed to assembly of the
pressure valve.

3.

Thread the positioning head onto the I.F.P locator tool and
adjust the top of the value indicator to the appropriate
measurement. Depending on which shock absorber is being
worked on, adjust the piston location tool to the specified
depth indicated in the shock 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 counter-bore. 

5.

Using the tool as a handle, push the floating piston down
into the shock body, being careful not to damage I.F.P 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.lb 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. 

8.

With the cylinder head assembly pushed down against the
piston, carefully, insert the piston rod and assembly into the
cylinder; Slightly oscillating the piston rod to allow piston
to enter shock body bore. A light coating of oil on the piston
wear band will ease installation. 

9.

Slowly push the piston rod and assembly into 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 piston assembly.

10. During installation, some shock oil will overflow. Wrap a

shop cloth around shock body to catch possible oil
overflow. Fast installation of the piston rod and assembly
may displace the floating piston from its original position.
This must not occur if the damper is expected to perform
as designed.

11. Using an open face spanner wrench tighten cylinder head

securely into the shock cylinder. 

12. Pressurize the shock, through the pressure valve, with

nitrogen gas to the specified pressure.

13. If using RydeFX inflation tool Refer to Procedures for use

of replaceable inflation needle instruction manual found in
the RydeFX inflation tool case.

14. After being compressed, the piston rod should fully extend

from the shock body once the shock has been pressurized.

15. Install the small button head screw in the pressure valve

assembly and tighten securely.

16. Reinstall sleeve and bushings in lower shock mount.

10.32

Rear Suspension

Rev. 1 07/2006

FOX PS-5 DISASSEMBLY

1.

Remove the shock from the vehicle.

2.

Remove the steel sleeve from the eyelet using the mallet
and an appropriate sized socket.

3.

Pry the polyurethane bushings out using the flat blade
screwdriver, being careful not to scratch the body cap.

4.

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 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.

5.

Use a 3/32" Hex Key to remove the button head screw from
the FOX air valve in the shock body.

6.

Securely clamp Fox Nitrogen Safety Needle in vice.

7.

Insert the Fox Safety Needle squarely into center of gas
valve. 

8.

Using a blunt object, depress the air valve core to release
pressure.

9.

When the shock is FULLY DISCHARGED, pull reservoir
away from the Fox Safety Needle in a straight, smooth
motion.

10. Clamp the body end eyelet of the shock securely in vice

with shaft side up.

11. 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.

12. 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.

13. 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 old shock oil.

14. Using the handle of the mallet, push the IFP out of the shock

body on to a folded shop towel. 

15. Remove the bleed screw from the IFP using the 1/8" T-

Handle

16. 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 and let sit in a well
ventilated area to allow the solvents to evaporate.

17. Set body assembly aside on a clean, lint free towel.

18. Clamp the shaft eyelet securely in vice with the piston end

up.

19. Using a 9/16" wrench, remove the piston lock nut from the

end of the shaft.

20. 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. 

21. 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.

22. Remove the bleed screw from the IFP and set them both on

a clean, lint free towel. 

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
of o-ring, use the non-writing end of a pen, or a similar soft,
blunt object, to push it in.

CAUTION

Point air valve away from face and body when charging 

or discharging any shock.

 

 

 

 

 

 

 

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