2004 Polaris Touring Service Manual, Page 242Get this manual
SUSPENSION Apply thin film of oil onto the floating wear band and Oring and install the floating piston into the top of the shock body, positioning it below the counterbore(PICTURE 13)
13 Using the tool as 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 bodyThe piston should now be located correctly(PICTURE 14)
Apply of light film of grease to the pressure valve port counter bore through 360 Degrees, where the pressure valve assembly Oring meetsScrew the pressure valve assembly into the valve port by hand with slotted head screwdriver; and tighten to 100110 in.lb of torque(PICTURE 15) Fill the shock body with shock oil: A) Internal Floating Piston Shocks: Fill the shock body with shock oil to the bottom of the thread within the cylinderB) Emulsion Shocks: Fill shock body with 110cc's of oilThis will allow for the required air space to properly gas charge the shock with nitrogen gasNOTE: After filling the shock body with oil, allow couple of minutes for all air bubbles to rise to the top