Snowmobile Polaris 600 RUSH (2010 year). Manual - part 57

7.18

Shocks

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

12. Set the IFP so it is approximately 1/8 from the bottom 

of the reservoir. Install the bleed screw.

13. With the cylinder head assembly pushed down 

against the valve piston, dip the piston assembly in 
shock oil.

14. Fill the shock body with oil to the bottom of the threads. 

Carefully insert the piston rod and valve assembly into 
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 
(IFP) from its original position. Performance issues 
will be a result if the IFP is not in its specified position.

16. Tighten the cylinder head onto the shock body.

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.

7.19

Shocks

7

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

FOX IFP Monotube Shock Disassembly

Shock Components (IFP Air Bleed)

Shock Components (Bearing Air Bleed)

SHOCK ROD

IF

P DEP

T

H

O-RINGS

WEARBAND

IFP

BLEED SCREW

O-RING

BLEED SCREW

FILL PORT

SPRING RETAINER

PISTON

WEARBAND

BODY CAP

O-RING

LOCK NUT

BACKUP PLATE

BEARING

WIPER

ICE SCRAPER

RETAINER

EYELET

BUSHING

REBOUND STACK

COMPRESSION STACK

TOP OUT PLATE

SPRING GUIDE

O-RING

SHOCK ROD

IF

P DEP

T

H

O-RINGS

WEARBAND

IFP

O-RING

BLEED SCREW

FILL PORT

SPRING RETAINER

PISTON

WEARBAND

BODY CAP

O-RING

LOCK NUT

BACKUP PLATE

BEARING

WIPER

ICE SCRAPER

RETAINER

EYELET

BUSHING

REBOUND STACK

COMPRESSION STACK

TOP OUT PLATE

SPRING GUIDE

AIR VALVE/SET SCREW

7.20

Shocks

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

Shock Disassembly

1.

Remove the shock from the vehicle. Clean the shock 
assembly to remove all dirt and foreign material. 
Inspect the assembly for any noticeable signs of 
damage.

2.

Clamp the body cap end of the shock in a soft-jawed 
bench vise.

3.

Remove the bleed screw from the fill port. Insert the 
needle of the gas fill tool, PN PS-45259, into the fill 
port to depressurize the shock. Push the shock rod 
down to ensure all nitrogen is expelled. Remove the 
fill port from the body cap.

4.

Remove the bearing assembly from the shock body. 
Remove the bearing assembly/shock rod from the 
shock body.

5.

Release the bench vise and drain all of the oil out of 
the shock body into a suitable container. Discard the 
oil in accordances with local rules and regulations.

6.

Position the bearing cap end of the shock over a clean 
shop towel on the bench. Use compressed air applied 
to the fill port bore to push the IFP out of the shock 
body.

7.

Using the shock body holding tool, PN 2871071, 
clamp the shock body with the body cap pointed up 
in a bench vise. Remove the body cap from the tube.

8.

Remove the lock nut from the shock rod. Remove the 
backup plate, rebound stack, piston, compression 
stack, and top-out plates as one assembly. Orientate 
these components on a clean shop towel as they are 
assembled on the shock rod.

9.

Remove the shock rod from the bearing.

10. With the shock disassembled, inspect all o-rings, 

wiper, wearbands, and the ice scraper. It is 
recommended that all be replaced with new parts.

11. Inspect the shock rod and shock body tube for 

damage and/or pitting.

12. Inspect the rebound and compression stack valve 

shims. Shims that are damaged, bent, chipped, or 
wavy in appearance must be replaced.

13. Thoroughly clean all parts and dry with compressed 

air.

FOX IFP Monotube Shock Assembly

Shock Assembly - IFP Air Bleed Shocks

1.

Place the shock rod eyelet in the bench vise. Apply a 
liberal amount of shock oil to the surface of the shock 
rod and internal bore of the bearing.

NOTE:  Install jounce bumper if equipped.

2.

Place the seal protector, PN 2201639, over the 
threaded end of the shock rod. Carefully install the 
bearing onto the shock rod.

3.

Install the topout plate, and compression valve stack. 
Use a Vernier Caliper and reference the valve stack 
specifications in this chapter if unsure of the shim 
order of assembly.

4.

Install a new wearband on the piston valve. Lubricate 
the piston with shock oil. Install the piston with the 
greater number of relief ports facing up away from the 
compression stack.

5.

Install the rebound valve stack. Again, if unsure of 
order of shims, use a Vernier Caliper and reference 
the valve stack specifications for the shock in this 
chapter.

6.

Install the backup plate. Remove the seal protector 
and install a new lock nut. Torque lock nut to 15-20 ft-
lb (20-27 Nm).

7.

Remove the shock rod from the bench vise. Secure 
the shock body with shock body holding tool in the 
vise.

8.

Install the bearing/shock rod assembly into the body 
tube. Tighten securely. Remove shock body from 
vise. Secure shock rod eyelet in bench vise.

9.

With the shock rod eyelet mounted in the vise, and the 
body cap end of the shock pointed up, slowly fill 3/4 
of the body tube with new shock oil.

10. Allow the oil to sit for several minutes to allow air 

bubbles to escape. Gently tap on the shock body to 
assist in removing any trapped air.

CAUTION

SHOCK CONTENTS UNDER HIGH PRESSURE. 

ALWAYS WEAR SAFETY GLASSES WHEN 

WORKING WITH SHOCKS.

CAUTION

SHOCK CONTENTS UNDER HIGH PRESSURE. 

ALWAYS WEAR SAFETY GLASSES WHEN 

WORKING WITH SHOCKS.

Fox 5W Shock Oil

2870995(Quart)

7.21

Shocks

7

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

11. After a few minutes, slowly and carefully pump the 

shock body up and down to force the oil through the 
valves stacks and piston orifices. Continue until air 
bubbles no longer rise to the surface of the oil.

12. After removing all of the air from the shock oil, collapse 

the shock rod into the shock body.

13. Remove the bleed screw from the IFP. Install a new 

o-ring and wearband onto the IFP. Lubricate the 
assembly with shock oil.

14. Set the depth of the IFP locator tool, PN 2871351, with 

a Vernier Caliper. The IFP depth specifications are 
noted for all rebuildable shocks in this chapter.

15. Slowly push the IFP down into the shock body until the 

IFP locator tool bottoms-out on the tube. Tap on the 
shock body to remove any air trapped under the IFP.

NOTE: The IFP must be completely submerged in 
shock oil to ensure air does not become trapped 
under the IFP.

16. With the IFP correctly set inside the tube, install the 

IFP bleed screw. Make sure not to move the shock rod 
after installing the screw as doing so will move the IFP.

17. Remove the shock from the bench vise and pour out 

the remaining shock oil into a suitable container.

18. Install the body cap onto the shock body. Tighten 

securely.

19. Reinstall the fill port. Charge the shock with nitrogen 

to the specified pressure using the gas fill tool, PN PS-
45259. The shock rod should be pushed outwards as 
the IFP compresses the shock oil.

20. Remove the fill tool from the fill port and reinstall the 

bleed screw.

21. Test shock by pushing down on the shock rod. The rod 

should extend slowly after pushing it into the tube with 
no sound of trapped air inside the oil. If the sound of 
air is present or the rate of shock rod compression or 
extension dramatically changes, the shock should be 
disassembled and the oil replaced.

FOX IFP Monotube Shock Assembly

Shock Assembly - Bearing Air Bleed Shocks

1.

Place the shock rod eyelet in the bench vise. Apply a 
liberal amount of shock oil to the surface of the shock 
rod and internal bore of the bearing.

NOTE:  Install jounce bumper if equipped.

2.

Place the seal protector, PN 2201639, over the 
threaded end of the shock rod. Carefully install the 
bearing onto the shock rod.

3.

Install the topout plate, and compression valve stack. 
Use a Vernier Caliper and reference the valve stack 
specifications in this chapter if unsure of the shim 
order of assembly.

4.

Install a new wearband on the piston valve. Lubricate 
the piston with shock oil. Install the piston with the 
greater number of relief ports facing up away from the 
compression stack.

5.

Install the rebound valve stack. Again, if unsure of 
order of shims, use a Vernier Caliper and reference 
the valve stack specifications for the shock in this 
chapter.

6.

Install the backup plate. Remove the seal protector 
and install a new lock nut. Torque lock nut to 15-20 ft-
lb (20-27 Nm).

7.

Remove the shock rod from the bench vise. Secure 
the shock body with shock body holding tool in the 
vise.

8.

With the body cap removed from the shock body, the 
IFP must be installed as shown in the illustration. 
Install a new o-ring and wearband onto the IFP. 
Lubricate the assembly with shock oil.

9.

Set the depth of the IFP locator tool, PN 2871351, with 
a Vernier Caliper. The IFP depth specifications are 
noted for all rebuildable shocks in this chapter.

10. Slowly push the IFP down into the shock body until the 

IFP locator tool bottoms-out on the tube.

11. Install the gas fill port bleed screw into the body cap. 

Install a new body cap o-ring, and then reinstall the 
body cap.  Tighten securely.

NOTE: The IFP should now be set in the correct 
position inside the shock body.

CAUTION

SHOCK CONTENTS UNDER HIGH PRESSURE. 

ALWAYS WEAR SAFETY GLASSES WHEN 

WORKING WITH SHOCKS.