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How to rebuild a shock??
- Any info and tips??
started by sledfreak139
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October 3rd 2009 at 6:55 PM
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sledfreak139
Sled Junky
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368 Posts 
Group: Members
Member Since: March 12th 2009
Location: Derry, NH, USA
Current Sled: 05 Polaris Switchback 600
2008-2009 Miles: 400
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I am thinking about rebuilding my shocks myself and then just bringing them to the dealer to be pressurized with nitrogen to save myself a couple hundred bucks. I have about 6 shocks to do so the dealer is going to be wayyy to pricey. Any info and tips on how to rebuild one? Thanks!
2005 Polaris Switchback 600: SlyDog PowderHound Ski's, SLP Air Box Mod, V-Force 3 Reeds, 144" track fully studded, Powermadd Pivot Riser and 4" block, Polaris Hand guards,
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Site Supporter
Group: Site Supporters
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October 3rd 2009 at 8:20 PM
[ Modified October 3rd 2009 at 8:20 PM
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MNSLEDNECK56308
Senior Member
MNSLEDNECK56308 done working on trailer for the night!
Updated Thursday at 10:44 PM
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2710 Posts 
Group: Moderators
Member Since: January 12th 2004
Location: ALEXANDRIA, MN, USA
2008-2009 Miles: 1043
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find someone local! If you have never done a shock don't waste your time as you wont have the right equipment and supplies! I'm sending mine to a site sponsor Diamond shocks, he will hook you up!
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October 3rd 2009 at 8:33 PM
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arcticcatinc
Sabercat Fever!
arcticcatinc if your going to watch "new moon" tonight..or ever for that matter. Your gay.
Updated Thursday at 7:06 PM
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2510 Posts 
Group: Members
Member Since: November 16th 2005
Location: Owosso, Michigan, USA
Current Sled: 2004 SaberCat 700 EFI
2008-2009 Miles: 2159
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took mine to a local guy. $60 a shock... would of rather paid 40 =D
Trenton Bailey
2004 Sabercat EFI 700 (Red)
2002 ZL 600 EFI SS *sold* (Orange)
2001 Z370 (Green)
**
2005 Ford Explorer 4X4
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October 3rd 2009 at 8:43 PM
[ Modified October 3rd 2009 at 8:45 PM
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Dman
Average Member
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528 Posts 
Group: Members
Member Since: February 13th 2004
Location: Shell Lake, WI
Current Sled: 98 XC600's (2)
2008-2009 Miles: 150
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I started doing mine last year. It's pretty easy. There's a nice thread on DooTalk I think that I learned a lot from...search over there.
About the only thing you may need is the collets to hold the shocks and the nitrogen that are a little pricey. Seals etc are fairly cheap. I bet I have $2 per shock into mine.
You can build the filler needle for about $8. Trust me, I did.
I use Amsoil oil.
I wish I would have read this earlier. I just did 4 shocks today. I could have taken pics for you.
D
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October 3rd 2009 at 9:01 PM
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skidogger
Average Member
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707 Posts
Group: Members
Member Since: September 4th 2006
Location: NH, USA
Current Sled: 09 skidoo mxzx 600 etec
2008-2009 Miles: 3100
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Get the factory manual. It should have any specs or directions that are specific for THAT shock, (at least ski doo does). It will also tell you what special tools you may need, how much oil to put in, etc.
If you are doing 6 shocks, anything you buy to do them yourself will still be cheaper.
The first one you do will be a little difficult. The last one will be pretty easy.
Just remember to release ALL the pressure in the shock before you take it apart.
If they don't leak now and they perform the way you want, just replace the oil and recharge it. That's all I do and never had any problems, and I don't replace the seals.
Scott.
150+ mi per tank of gas/ 1200 mi per tank of 2 stroke oil!
^Take that 4 strokes!!
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October 3rd 2009 at 9:41 PM
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sledfreak139
Sled Junky
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368 Posts
Group: Members
Member Since: March 12th 2009
Location: Derry, NH, USA
Current Sled: 05 Polaris Switchback 600
2008-2009 Miles: 400
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Thanks for the replies guys! Well I'd rather not buy a manual which is why I posted here. If anyone could tell me specifically what tools to buy, maybe even include links to them so theres no confusion, and a few instructions on how to do each step. I would probably just bring it somewhere to have it pressurized but other than that I can probably do the rest with a little help from you guys  I have the tool to get the springs off the shocks also.
2005 Polaris Switchback 600: SlyDog PowderHound Ski's, SLP Air Box Mod, V-Force 3 Reeds, 144" track fully studded, Powermadd Pivot Riser and 4" block, Polaris Hand guards,
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October 3rd 2009 at 9:52 PM
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ACG
Sell-Out - Moderator
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9086 Posts
Group: Moderators
Member Since: October 29th 2001
Location: Bountiful, UT, USA
Current Sled: 2009 Dragon 800
2008-2009 Miles: 1500
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Quote originally posted by sledfreak139
Thanks for the replies guys! Well I'd rather not buy a manual which is why I posted here. If anyone could tell me specifically what tools to buy, maybe even include links to them so theres no confusion, and a few instructions on how to do each step. I would probably just bring it somewhere to have it pressurized but other than that I can probably do the rest with a little help from you guys I have the tool to get the springs off the shocks also.
Why don't you want to buy a manual? they are cheap and you will know you have done it right when you are done....
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October 3rd 2009 at 10:04 PM
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Mad-Boondocker
Only way to take on FEAR is to take it head on
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751 Posts
Group: Members
Member Since: February 19th 2009
Location: East Otto, NY, USA
Current Sled: 98 Polaris Indy 500 Mod
2008-2009 Miles: 185
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It sounds like it is cheaper to do it yourself but a little complicated
1998 Polaris Indy 500 chassis with 98 Xc 600 motor
SLP ceramic coated pipe with SLP can
V-force reeds
4 inch pivot riser
Gutted Air Box
EPI clutch kit soon to be installed
Maybe some pro tapers
1998 XC 700 water-cross sled
SLP twin pipes
Some light weight parts
Water-cross mods include taking the parts u do not need
This includes removing the seat replacing gas tank and IFS bars.
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October 3rd 2009 at 10:05 PM
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sledfreak139
Sled Junky
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368 Posts
Group: Members
Member Since: March 12th 2009
Location: Derry, NH, USA
Current Sled: 05 Polaris Switchback 600
2008-2009 Miles: 400
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Quote originally posted by ACG
Quote originally posted by sledfreak139
Thanks for the replies guys! Well I'd rather not buy a manual which is why I posted here. If anyone could tell me specifically what tools to buy, maybe even include links to them so theres no confusion, and a few instructions on how to do each step. I would probably just bring it somewhere to have it pressurized but other than that I can probably do the rest with a little help from you guys I have the tool to get the springs off the shocks also.
Why don't you want to buy a manual? they are cheap and you will know you have done it right when you are done....
I was hoping one of you guys could give me a few instructions on what to do. I am mechanically inclined and don't have a problem just diving right in but just wanted some details on some tips and helpful info... 
2005 Polaris Switchback 600: SlyDog PowderHound Ski's, SLP Air Box Mod, V-Force 3 Reeds, 144" track fully studded, Powermadd Pivot Riser and 4" block, Polaris Hand guards,
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October 4th 2009 at 12:15 AM
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XLT96rider
Other sports play once a week, but this sport is with us every day.
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942 Posts
Group: Members
Member Since: January 7th 2009
Location: Wausau, Wisconsin, USA
Current Sled: 1996 Polaris XLT Special
2008-2009 Miles: 1000+
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Quote originally posted by sledfreak139
I am mechanically inclined and don't have a problem just diving right in but just wanted some details on some tips and helpful info...
Same here, but I opted to pay the $50/pc and know they are done right.
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October 4th 2009 at 8:29 AM
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sledfreak139
Sled Junky
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368 Posts
Group: Members
Member Since: March 12th 2009
Location: Derry, NH, USA
Current Sled: 05 Polaris Switchback 600
2008-2009 Miles: 400
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Quote originally posted by XLT96rider
Quote originally posted by sledfreak139
I am mechanically inclined and don't have a problem just diving right in but just wanted some details on some tips and helpful info...
Same here, but I opted to pay the $50/pc and know they are done right.
My Dealer wants $105 each...
2005 Polaris Switchback 600: SlyDog PowderHound Ski's, SLP Air Box Mod, V-Force 3 Reeds, 144" track fully studded, Powermadd Pivot Riser and 4" block, Polaris Hand guards,
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October 4th 2009 at 8:50 AM
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Dman
Average Member
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528 Posts
Group: Members
Member Since: February 13th 2004
Location: Shell Lake, WI
Current Sled: 98 XC600's (2)
2008-2009 Miles: 150
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deycore.com for tools and components.
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October 4th 2009 at 7:10 PM
[ Modified October 4th 2009 at 7:11 PM
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Quote originally posted by Dman deycore.com for tools and components. just send them to deycore. its cheap and deycore rules
---------------------------
- 2004 pro-xr 440/800: SLP single pipe, clutched, not enough studs, wacky oil tank mounting, crazy intake i made, REV seat/tank, C&A pro skis.
- 2006 mxzx 440 race sled
- 1989 indy trail
- 2001 800xcsp: rest in pieces.
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October 5th 2009 at 12:13 AM
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sledfreak139
Sled Junky
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368 Posts
Group: Members
Member Since: March 12th 2009
Location: Derry, NH, USA
Current Sled: 05 Polaris Switchback 600
2008-2009 Miles: 400
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For the amount of sleds I work on before a season, I think it would be worth the time and money to learn how to do it and buy the tools... I checked out that site, they have a ton of different tools and what not. any experience with any of the tools on that site?
2005 Polaris Switchback 600: SlyDog PowderHound Ski's, SLP Air Box Mod, V-Force 3 Reeds, 144" track fully studded, Powermadd Pivot Riser and 4" block, Polaris Hand guards,
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October 5th 2009 at 7:24 PM
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Dman
Average Member
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528 Posts
Group: Members
Member Since: February 13th 2004
Location: Shell Lake, WI
Current Sled: 98 XC600's (2)
2008-2009 Miles: 150
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I suppose it depends on how many different shocks you are going to rebuild. The 'holders'-collets, are different sizes for the diameter's of different shocks. I've been fortunate that all my buddy's have Fox that are all the same size.
Filler, Collets, seals, nitrogen tank are all about you need.
D
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October 5th 2009 at 10:41 PM
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XCR_NUTS
Starting Member
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16 Posts
Group: Members
Member Since: October 12th 2008
Location: Moorhead, MN, USA
Current Sled: 1998 XCR 440
2008-2009 Miles: 2000
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Joe, you are right, if you can do most mechanical things on your sled, you can do this.
You will need the blocks to hold the shock body and the shaft. This is 2 sets of blocks. I bought mine a couple years ago from my Polaris dealer. I believe he charged me 60 bucks for them. You will also need the condom that goes over the shaft threads when you reinstall into the seals, again this was about 15 bucks or so. As said before the charge needle prolly can be made at home, but I also bought that. All in all the money I spent on tools alone was cheaper than having someone else do it. Yup I got the nitrogen set up to recharge them too. But then again, me and a few friends here ALL have Fox or ACT shocks, so was worth the investment.
If you want details how to do it, feel free to PM me you number and I will call you and explain it. I have and awesome cell plan. It is WAY easier to explain with words spoken then to type. Remember some of us use the "Hunt and Peck" method to type.
1998 XCR 440
1996 XCR 600
1995 XCR 600
1994 XCR 600
1999 XC 500
2000 ZR 500
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October 6th 2009 at 9:10 AM
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MX86
Powder Rider
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1640 Posts 
Group: Members
Member Since: March 1st 2007
Location: Nashwauk, Minnesota, USA
Current Sled: 1999 polaris 700 SKS mod
2008-2009 Miles: not enough
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Key is to make sure you set the IFP depth on each shock correctly
2006 Yamaha YZ250
KYB SSS Suspension w/ Race Tech G2 gold Valve, ASV F3 levers, Tag Metals Triple clamp w/Pro Taper Bars, IMS Pro Series Pegs, Motion Pro Twist Throttle Assembly, VF3 Reeds
Thanks to my newest 09 Sponsors:
Gravity Worx Racing
Duner Central
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October 6th 2009 at 9:49 AM
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Zippi
Average Member
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537 Posts
Group: Members
Member Since: November 7th 2005
Location: Groton, NY, USA
2008-2009 Miles: 1300
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Quote originally posted by MX86
Key is to make sure you set the IFP depth on each shock correctly
unless they have a bladder...very simple if you have all the correct tools. Careful with the seal heads.
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October 6th 2009 at 10:30 AM
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Geiger
Starting Member
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24 Posts
Group: Members
Member Since: August 6th 2009
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theres a guy on craigslist that rebuilds them with all new stuff and fills them with amsoil, and charges them for $25 apiece. Sending him my rear shock here sometime. Ill tell you how he does.
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October 6th 2009 at 11:20 AM
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sledfreak139
Sled Junky
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368 Posts
Group: Members
Member Since: March 12th 2009
Location: Derry, NH, USA
Current Sled: 05 Polaris Switchback 600
2008-2009 Miles: 400
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Thanks for your help guys! I am going to look through that site and see what tools I need to buy and post the links to make sure I'm getting the right tools. If anyone has a whole set up that they just don't use anymore, I would definitely be interested.
2005 Polaris Switchback 600: SlyDog PowderHound Ski's, SLP Air Box Mod, V-Force 3 Reeds, 144" track fully studded, Powermadd Pivot Riser and 4" block, Polaris Hand guards,
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October 6th 2009 at 8:51 PM
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Zippi
Average Member
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537 Posts
Group: Members
Member Since: November 7th 2005
Location: Groton, NY, USA
2008-2009 Miles: 1300
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Quote originally posted by Geiger
theres a guy on craigslist that rebuilds them with all new stuff and fills them with amsoil, and charges them for $25 apiece. Sending him my rear shock here sometime. Ill tell you how he does.
new valves and a seal head alone cost more than that. Guarantee he puts in new oil, recharges, and sends it back.
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October 6th 2009 at 9:09 PM
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arcticcatmatt
Spleen Splitter
arcticcatmatt leaving after work for 3 days of shotgun season back home!
Updated Friday at 12:16 PM
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14007 Posts
Group: Moderators
Member Since: November 25th 2001
Location: Berkshire, NY, USA
Current Sled: 96/97 ZRT 600
2008-2009 Miles: 450
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^ Listen to Zip.. he sleeps with suspension
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October 6th 2009 at 9:32 PM
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MX86
Powder Rider
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1640 Posts
Group: Members
Member Since: March 1st 2007
Location: Nashwauk, Minnesota, USA
Current Sled: 1999 polaris 700 SKS mod
2008-2009 Miles: not enough
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Quote originally posted by arcticcatmatt
^ Listen to Zip.. he sleeps with suspension
I seen what he sleeps with, and if he sleeps with a shock i'm going to call him a homo
2006 Yamaha YZ250
KYB SSS Suspension w/ Race Tech G2 gold Valve, ASV F3 levers, Tag Metals Triple clamp w/Pro Taper Bars, IMS Pro Series Pegs, Motion Pro Twist Throttle Assembly, VF3 Reeds
Thanks to my newest 09 Sponsors:
Gravity Worx Racing
Duner Central
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October 6th 2009 at 9:34 PM
[ Modified October 6th 2009 at 9:36 PM
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Quinlan
Department of Corrections
Quinlan is a little disappointed that he received HMK Highmark 4 boots instead of the Highmark Pros as he had anticipated...
Updated Friday at 6:19 PM
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9723 Posts
Group: Moderators
Member Since: December 8th 2003
Location: Fargo, ND, USA
Current Sled: 06 SP 440/700, 98 ZR 600
2008-2009 Miles: 365
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Now, now, Matt. What you THOUGHT you heard was "He sleeps with Shocks." In reality, it was "He sleeps with co..." ...Nevermind...  
2006 Arctic Cat SnoPro 440/700 EFI
1998 Arctic Cat ZR 600 EFI Custom
1996 Ski-Doo FormulaIII 600
A mountain lion roaming the prairie found a bull, killed it and ate the entire bull. With a heavy belly, unable to walk, the lion laid in the tall grass moaning and roaring. Soon a hunter, attracted by the roaring, shot and killed the lion.
Moral: When you're full of bull, keep your mouth shut!
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Wednesday at 1:27 PM
[ Modified Wednesday at 1:30 PM
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THE_Norwegian
:)
THE_Norwegian got some SLP powder pro skis in the mail today :-D.
Updated Friday at 5:32 PM
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446 Posts
Group: Members
Member Since: January 29th 2008
Location: Norway
Current Sled: ET 340 and XCR 440
2008-2009 Miles: 2500KM :-D
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i decided to rebuild my shocks because the delaer wanted over 100$ per shock. i hav a polaris manual and rebuilding seems prett easy one thing, on my shock there no IFP. so all i have to do is change all seals/0-rings and fill the bottom with oil, and the top with nitrogen ?
* XCR 440 *
"I`m not picking my nose.. I´m porting my head!"
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