Snowmobile Polaris (2006 year). Manual - part 60

11.22

REAR SUSPENSION

WALKER EVANS SHOCK VALVE PART
NUMBERS

SHOCK VALVING ARRANGEMENT

Shown below is an example of how valving stacks are
arranged. The Production Shock Information contain
production valving specifications and piston orifice sizes.

Parts in the box below are an example of standard valving.

NOTE: Note the direction of the valve piston before
disassembly. The side with the greater number of
relief slots (1) should face the nut end (2) of the
shaft.

Table 11-23:

PART NUMBER

SIZE

THICKNESS

1800051

.700

.006

1800075

.800

1800076

.900

1800077

1.000

1800078

1.100

1800079

1.200

1800080

1.300

1800081

.700

.008

1800082

.800

1800083

.900

1800084

1.000

1800085

1.100

1800086

1.200

1800087

1.250

1800088

1.300

1800052

.700

.010

1800053

.800

1800054

.900

1800055

1.000

1800056

1.100

1800057

1.200

1800058

1.300

1800059

.700

.012

1800060

.800

1800061

.900

1800062

1.000

1800063

1.100

1800064

1.200

1800089

1.250

1800072

1.300

1800066

.700

.015

1800067

.800

1800068

.900

1800069

1.000

1800070

1.100

1800071

1.250

1800072

1.300

1800090

1.000

.025

1800091

1.100

1800092

1.200

1800093

1.300

1800050

.625

.065

1800204

.875

.090

11.23

REAR SUSPENSION

SPECIAL TOOLS

SHOCK REBUILDING TOOLS

SHOCK MAINTENANCE

Changing oil on Shocks is recommended annually and should
be included when performing end of season storage
preparation. This oil change is necessary to avoid any chance
of corrosion which could be caused by moisture
contamination.

When performing maintenance on Shocks, use Gas Shock
Recharging Kit PN 2200421. It 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 your
SPX Specialty Tool catalog for part numbers.Videos on shock

Table 11-24: 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

Table 11-25: 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

Table 11-26: 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

11.24

REAR SUSPENSION

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.

Remove the shock(s) from the vehicle.

Before unscrewing pre-load springs, measure the
compressed length of the installed spring and mark
position for reinstallation.

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

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

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.

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

Depressurize the shock.

Internal Floating Piston Shocks, using a 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 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.

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

CAUTION

XTREME

CAUTION

SHOULD

OBSERVED

WHILE

HANDLING

AND

WORKING

WITH

HIGH

PRESSURE

SERVICE

EQUIPMENT

EAR

FACE

SHIELD

SAFETY

GLASSES

AND

EAR

PROTEC

TION

DURING

SERVICE

THESE

SHOCKS

. C

ARE

SHOULD

OBSERVED

WHILE

HANDLING

THE

INFLATER

NEEDLE

AND

PRESSURE

GAUGES

. M

AINTAIN

YOUR

EQUIPMENT

AND

KEEP

GOOD

WORKING

CONDITION

. I

INJURY

SHOULD

OCCUR

CONSULT

PHYSICIAN

IMMEDIATELY

. E

XTREME

CLEANLI

NESS

UTMOST

IMPORTANCE

DURING

ALL

DISASSEMBLY

AND

REASSEMBLY

OPERATIONS

PREVENT

ANY

DIRT

FOREIGN

PARTICLES

FROM

GETTING

INTO

THE

SHOCKS

EEP

THE

PARTS

ORDER

THEY

ARE

DISASSEMBLED

OTE

THE

DIRECTION

AND

POSITION

ALL

INTERNAL

PARTS

FOR

REASSEMBLY

CAUTION

EFORE

SERVICING

GAS

SHOCK

IMPORTANT

THAT

ALL

THE

GAS

PRESSURE

DISCHARGED

FROM

THE

UNIT

EFER

THE

INSTRUCTIONS

LISTED

BELOW

FOR

THE

PROPER

PROCEDURE

DISCHARGING

THE

GAS

PRES

SURE

FROM

SHOCK

. P

ROTECTIVE

EYE

WEAR

SHOULD

WORN

AVOID

RISK

INJURY

WHILE

SERVICING

GAS

CHARGED

MONO

TUBE

SHOCKS

CAUTION

HEN

REMOVING

THE

SPRING

FROM

SHOCK

THAT

UTILIZ

FIXED

LOWER

RETAINER

;

THE

USE

PROPER

SPRING

COMPRESSOR

SHOULD

USED

AVOID

RISK

BODILY

INJURY

WARNING

HEN

USING

COMPRESSED

AIR

DRY

COMPONENTS

PROTECTIVE

EYE

WEAR

SHOULD

WORN

AVOID

RISK

INJURY

CAUTION

IMPORTANT

THAT

THE

GAS

SHOCK

RETAINED

THE

VISE

THE

LOWER

MOUNT

. A

OTHER

METHOD

SECURING

THE

CHOCK

BODY

DURING

THESE

PRO

CEDURES

MAY

DEFORM

THE

SHOCK

BODY

CYLINDER

WARNING

ITROGEN

GAS

UNDER

EXTREME

PRESSURE

USE

CAUTION

WHEN

RELEASING

NITROGEN

GAS

FROM

SHOCK

. P

ROTECTIVE

EYE

WEAR

SHOULD

WORN

AVOID

RISK

INJURY

11.25

REAR SUSPENSION

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

FOX PS-5 DISASSEMBLY

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

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