2004 Polaris Touring Service Manual, Page 243Get this manual
SUSPENSION 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 boreA light coating of oil on the piston wear band will ease installation(PICTURE 17) Slowly push the piston rod and assembly into shock body until the cylinder head assembly bottoms on the cylinder counterboreSlight up and down movement may be required to allow all air to pass through piston assemblyNOTE: During installation, some shock oil will overflowWrap shop cloth around shock body to catch possible oil overflowFast installation of the piston rod and assembly may displace the floating piston from its original positionThis must not occur if the damper is expected to perform as designed Using an open face spanner wrench tighten cylinder head securely into the shock cylinder(PICTURE 18) 17