fox shocks rezzies..where to get them?

[400exdave]

my roomate has a 2004 Troy Lee Designs predator 500. unforanatley he has the year/model that didn't include the rezzies witht he front fox shocks. where can you buy those at? just the rezzies. thanks in advance.

[OutlawBill]

Polaris (http://www.purepolaris.com/Detail.aspx?ItemID=2874244(PolarisPGACatalog))

[browng31]

yep, only place to buy, fox makes 'em and can't even sell 'em due to an agreement with Polaris, called fox last week that' what they told me...

[katch26]

oh is that why?, I asked them (fox) about getting some springs for the shock and they told me I had to get them through Polaris (even though they dont sell them)

[katch26]

it would be cheaper to just buy a set of 05 or newer fox piggybacks

[browng31]

150 per shock for a rezzy from Polaris according to the PurePolaris site...

[interceptorz28]

My friend has them on his Raptor cause he didn't know they were the wrong size. Anyway, he wants to sell 'em. Pm if ya want em, make offer.

[shanekyle]

I got a great deal on a set of these rezzys but they didnt come the with instructions on how to put them on. Does anyone have that info they could scan in for me? I have rebuild many shocks before but never converted a set over to the remote resevior. I assume I just move the top plunger from the shock body to the rezzy, but then I am sure I would need to add more oil. Thanks for any help.

[coalrat]

-- 1 --
FOX RACING SHOCK FRONT RESERVOIR KIT
KIT P/N 2874244
Application
2003 Predator
Before you begin, read these instructions to familiarize yourself with all steps. Check to be sure all parts, tools, and
supplies are accounted for. Please retain these installation instructions for future reference and parts ordering information.
This kit includes:
Qty. Part Description . . . . . . . . . . . . . . . . . . . . . . . Fox Part No.
1 . . . . Bearing, External, Turcite . . . . . . . . . . . . . . . 002-00-000-A
1 . . . . Screw, 8-32 x .250”, Socket Cap . . . . . . . . . 018-01-003--A
1 . . . . 90 Degree Elbow, Brass, 1/8 x 27 . . . . . . . . 020-00-003-A
1 . . . . 90 Degree Elbow, Steel, 7/16 x 20 . . . . . . . 020-00-009-A
1 . . . . Hose, 16”, 1/8 x 27, with Swivel . . . . . . . . . 023-05-034-A
1 . . . . Decal, Podium, Reservoir . . . . . . . . . . . . . . . 024-00-051-A
1 . . . . Wire Retaining Ring, 1.375 I.D. . . . . . . . . . . 038-01-002-A
2 . . . . Wire Retaining Ring, 1.850 I.D. . . . . . . . . . . 038-01-005-A
1 . . . . Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . 227-02-006-C
2 . . . . Fox Logo Decal . . . . . . . . . . . . . . . . . . . . . . . 625-03-011-A
1 . . . . Reservoir Mounting Kit (Block/Clamp) . . . . 803-02-005-A
1 . . . . Floating Piston Assembly, w/O-ring . . . . . . 805-00-002-A
1 . . . . Reservoir End Cap Assembly . . . . . . . . . . . 813-00-019-A
1 . . . . Damping Adjust Assembly, Housing . . . . . . 815-00-021-A
1 . . . . Damping Adjust Assembly, Plate . . . . . . . . . 815-00-024-A
1 . . . . Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . Polaris P/N 9918522
You will need to supply:
1 3/8” Open-End Wrench or Large Crescent-Type wrench
Tape Measure Clean, Lint-Free Shop Towels
3/32” Hex Wrench Fox 5 wt. Shock Oil, 1 Quart
9/16” Open-End Wrench Fox Filler Needle Assembly
5/8” Open-End Wrench Compressed Nitrogen Gas
Flat Blade Screwdriver Assembly Grease
Soft-Faced Hammer 1/4--20 Bolt, Approximately 6” Long
APPROXIMATE INSTALLATION TIME: 1.5 Hours
IMPORTANT: Be sure to follow standard safety procedures. Wear safety glasses and use any other necessary safety
equipment.
INSTALLATION INSTRUCTIONS
1. Remove the right-hand shock from the vehicle.
2. Clean the shock thoroughly. Do not pressure wash
the shock assembly, as this may force water and
debris past the shaft seals and into the shock.
3. Measure the overall spring length as installed on the
shock. Record this measurement for later use.
4. Thread the spring preload collar towards the body
cap end to release tension on the spring.
5. Remove the spring retainer and the spring and set
aside.
-- 2 --
6. Remove the stainless steel button head screw from
the Fox air valve using the 3/32” hex wrench.
7. Using the Fox filler needle assembly (without the
gas supply line ), discharge the gas from the shock
body. Use extreme care in performing this step.
Make sure the filler opening is pointed in a safe
direction.
8. Remove the Fox air valve fromthe body cap using a
9/16” wrench. This component will not be reused.
9. Remove the urethane bushings and the steel sleeve
from the body cap end and set aside.
10. Clamp the shock in a
vise at the body cap
end, with the shaft end
up. To avoid damaging
the body cap, be sure to
use soft jaws in the
vise, or place a clean
rag in the jaws to
cushion the cap.
11. Remove the shaft
assembly from the
shock body using the
1-3/8” wrench. Set the
assembly aside on a
clean shop towel.
12. Remove the body
assembly from the
vise. Empty the used
shock oil into a suitable
container.
13. Fold several shop towels and place on a bench top.
Place the open end of the shock body on the towels.
14. Using low-pressure air, remove the internal
floating piston from the shock by blowing air into
the Fox Air Valve port on the body cap.
CAUTION! The floating piston will be forced out
with great force if high air pressure is used. Be very
careful to use low air pressure. Be sure to use a
cushion of towels to catch the piston.
15. Apply a small amount of assembly grease to the Fox
air valve port in the body cap.
16. Thread the 90 degree ORB fitting into the air valve
port. Tighten by hand. A wrench is not required to
tighten this fitting into place.
17. Hold the shock with the
body up, as it would be on
the vehicle. Position the
fitting at a 45 degree angle
down from horizontal.
The fitting end will point
towards the rear of the
vehicle. The fitting
positions on the right and
left shock will be mirror
images of each other.
18. When the fitting is in the
correct location, tighten
the lock nut securely by
hand. Then, using a 9/16”
wrench, tighten an
additional 1/8 turn. This
will push the o-ring into
the gland to seal the
fitting.
19. Attach the reservoir and hose assembly to the 90
degree fitting. Lay the shock flat on the bench, and
orient the reservoir so the bottom is angled
approximately 30 degrees above horizontal.
-- 3 --
20. Tighten the hose fitting finger tight. Tighten an
additional 1/4 turn with a 5/8” wrench.
21. Temporarily install the shock on the vehicle to
verify correct orientation of fittings and hose.
22. Place the body and reservoir assembly in the vise
with the body end up.
23. Locate the new large diameter internal floating
piston Lubricate the o-ring with assembly grease.
24. Fill the reservoir completely with fresh Fox shock
oil.
25. Insert the internal floating piston into the end of the
reservoir. The threaded boss faces out. Insert only
far enough to position the o-ring inside the
reservoir. Do not allow any air to enter the body.
26. Wind the included piston band around the groove in
the floating piston. Push the piston in fully.
27. Wrap a clean shop towel around the body near the
shaft end to catch any oil spillage.
28. Fill the shock body approximately 1/2 full with
fresh Fox shock oil.
NOTE: Steps 29 to 42 describe the procedure required
to purge the shock assembly of air. Follow these steps
carefully to ensure proper shock operation.
29. Insert the 1/4-20 x 6” bolt into the threads in the
bottom of the internal floating piston.
NOTE: Cycling the shockwill be easier if a simple
handle is welded to the end of the bolt before it is
attached to the piston. If this is not possible,
clamping a “Vise-Grip” type pliers to the end will
also help.
30. Hold the open end of the reservoir down to allow
any trapped air to escape.
31. Use the 1/4-20 bolt to slowly stroke the piston back
and forth to purge the air fromthe reservoir and hose
assembly.
32. Move the compression clicker to several positions
while moving the piston. Airwill be forced out into
the body.
33. Position the internal floating piston between 2-3/8”
and 2-1/2” from the open end of the reservoir and
place the compression clicker at position #8.
34. Fill the shock body until the oil level is
approximately even with the bottom of the internal
threads.
35. Place the piston wear band on the piston and insert
the shaft assembly into the oil.
36. Slowly stroke the piston through the oil several
times to remove any air trapped below the
assembly.
37. Hold the shaft assembly in line with the body and
strike the eyelet gently with a soft-faced hammer
several times. This will force the damping shims to
open and allow air trapped in the piston to comeout.
38. Air bubbles will be rising to the surface of the oil.
Do not continue until all the bubbles are gone.
39. Fill the body to within 1/4” of the end.
40. Pull the shaft assembly back until the shaft spacer
(or large top-out washer, if your spacer has been
removed) is near the surface of the oil.
41. Remove the 1/4-20 bolt.
42. Turn the compression clicker to position #1.
43. Insert the threaded bearing into the body, and thread
it fully into place. A small amount of oil should
spill over the edge of the shock body when you do
this. This will ensure that all air has been displaced
from the shock.
-- 4 --
44. Tighten the bearing into the end of the shock with
the 1-3/8” wrench. Do not overtighten.
45. Locate the reservoir end cap and the 1/16” diameter
wire ring. Lubricate the end cap o-ring with
assembly lube.
46. Insert the reservoir end cap into the reservoir. Push
it in until the wire ring can be inserted into the
internal groove.
47. Insert the wire ring. Make sure it is securely in
place.
48. Align the reservoir decal with the compression
clicker.
49. Use the Fox filler needle assembly to charge the
shock to 200 psi with compressed nitrogen gas.
Never use compressed air to charge the shock.
Doing so will result in very poor shock
performance.
50. Stroke the shock through its full travel several times
to ensure the assembly procedure was correctly
completed. Move the compression clicker to all
positions from #1 to #8 while cycling the shock to
ensure the entire mechanism is functioning
correctly.
51. Reinstall the bushings and sleeve into the body end
cap.
52. Install the stainless steel button-head screw
removed in step 6 into the Fox air valvewith a 3/32”
hex wrench.
53. Reinstall the spring and spring retainer.
54. Preload the spring to the length recorded in step 3.
55. Reinstall the shock into the vehicle and route the
reservoir and hose through the inner frame rails.
56. Using the mounting blocks and clamps to mount the
reservoir to the front frame member. Position with
the compression clicker facing up.
57. Repeat all steps for the left-hand shock.
58. Set both compression knobs to the #4 setting.
59. Test drive and readjust as desired.
PN 9918522 Rev 01 10/02
Printed in U.S.A.
Set as measured in step 3
Steps 45-47 Step 48 Step 49 Steps 55-56
Mount and route as shown

[coalrat]

Sorry no pics would copy and paste, pm me your email addy and i should be able to get them to you too

[Colby@C&DRacing]

We also sell the Fox ressie kits for those shocks