RZR XP 900 spring/shock installation Thank you for purchasing the Shock Therapy Dual Rate Spring Kit for your RZR 900. Your item list: 2 Front upper coil springs, 2 Front lower coil springs, 2 Rear upper springs, 2 Rear lower springs, 4 nylon spring dividers, 4 Silent cross over rings, 4 cross over ring O- rings, 8 aluminum spring adaptors (only for Fox equipped cars). You will need to get a coil spring compressor if you don’t already have one.
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RZRXP900spring/shockinstallationThankyouforpurchasingtheShockTherapyDualRateSpringKitforyourRZR900.Youritemlist:
2Frontuppercoilsprings,2Frontlowercoilsprings,2Rearuppersprings,2Rearlowersprings,4nylonspringdividers,4Silentcrossoverrings,4crossoverringO-rings,8aluminumspringadaptors(onlyforFoxequippedcars).Youwillneedtogetacoilspringcompressorifyoudon’talreadyhaveone.
Herearethesetupnotesforeach900springkit:
Fox2seatWalker2seatWalker4seat
Front:
Preload………..3.5”…………………….4”…………………………..1.750”
Crossover…….7.5”…………………….7”……………………………5.25”
Rear:
Preload………..2.25”…………………..2”……………………………1”
Crossover…….6”……………………….4”…………………………….3”
First,removeyourfrontshocksfromyourcar.BecarefulnottolosethemountingspacersandtheO-ringsthatareonthem.Placeoneshockinavice,upsidedownsobothofyourhandsarefree.Loosenthepreloadnutholdingtensiononthetopofthecoilsprings.OnaFoxthisistwo,ringsjammedtogether.Walkershocksuseasinglealuminumring.Youwillneedtospinorthreadtheseringstothetopoftheshocktoloosenthecoilspringsasmuchaspossible.Nowslidethebumpstopdowntheshockshaftabouttwoinches.Ifthespringislooseenoughyoucanpullthebottomspringretainerdownandslideitofftheshock.Ifthespringisstilltootightyouwillhavetouseaspringcompressortocompressthespringenoughtoremovethespringretainer.
(picaboveshowsWHEREtomeasurefromnotyourmeasurements)
Withtheretainerremovedyoucannowremovethefactoryspring.Now,measurewheretheroundthreadedshockbodyendsandtheheadoftheshockstarts,downtotheFRONTcrossoverlocationlistedonthefirstpageandmakeamarkontheshockbody.Forinstance,ifyouhaveaFoxequipped2seatRZRyouwillmakeamarkat3.5”.OurFoxkitsutilizeaspringadaptortoconvertthestockFoxpreloadnutandretainerto2.5”ODallowingittoacceptthecorrectspring.YouMUSTinstallthetopadaptorringFIRSTbeforeinstallingthecrossover.IfyouhaveaWalkerequippedcaryoudon’tneedanyspringadaptors.Next,installthecrossoverringwiththeroundrecessgroove(O-ringretainer)facingthebottomoftheshockrightatthemark.Usethesuppliedspannerwrenchtotightentheouterringlockingthecrossoverringinplace(Foxonly).
Now,youcaninstallthespringsasmarkedinyourkitwiththefront,upperspringfirst,thenthenylonspringdividerwiththelongsidefacingthebottomoftheshock(awayfromthecrossoverring)thenthefrontlowerspring.Makesuretheendsofthespringstouchtheplasticspringdivideronoppositesidesofthedivider.Anotherwaytoputthisisthatthespringsend180degreesapartfromeachotheronthedivider.Thiswillbeimportantlater.Usingyourspringcompressor,compressthespringsenoughtoinstallthelowerspringperchwithanotherspringadaptorring(Foxonly)betweenthecoilspringandthespringperch.Again,theWalkerequippedcardoesnotusetheadaptorrings.Withtheperchinplaceyoucanmovethebumpstoptoholdtheperchinplace.Nowletthetensionoffthesprings.Last,threadthepre-loadrings/collartowardthespringstighteningthesystem.Movethemdowntothepre-loadmeasurementlistedonthefirstpage.Thismeasurementisfromthesameplaceatthetopoftheshockdowntothetopoftheupperspringorthebottomofthespringadaptorring.Youcannowinstallthefrontshocksonyourcar.
Movetherearofthecarandremovetherearshocks.Withoneinavice,loosenthepre-loadcollarandremovethesprings.Youmayneedthespringcompressorforthis.Measurefromthetopwherethethreadedshockbodystopsandthetopcapoftheshockstarts,downandmakeamarkforyourrearcrossoverringlocation.Next,slidethespringadaptoron(Fox)andinstalltherearcrossoverringswiththeO-ringgroovefacingthebottomoftheshock.Tightenthecross
overandinstalltheO-ring.Now,installtheupperspring,nylondividerwiththelongsidefacingthebottomoftheshock,thenthelowerspring.Usethespringcompressorandinstallthelowerspringperchandloweradaptor(Fox).Releasethespringcompressorandthreadthepre-loadcollardowntothepre-loaddistancelistedonthefirstpage.Nowyoucaninstalltherearshocksonthecar.
InstallingyourshockswiththenewspringsisaprettystraightforwardthingtodobuttherearesomeadjustmentstotherideheightthatyoumustfollowtoensurethatyourRZRisatthecorrectheightforbestperformance.AllRZRsaredifferentweightsdependingontheaccessoriesyouhaveonitsoyoumayneedtoadjustthemalittletogetyourgroundclearancecorrect.
Onceyouhaveyourshocksinstalledyoumustdriveittosettlethesuspensionforanygroundclearancemeasurements.JustpushingtheRZRupanddownafewtimeswillnotwork!Onceyouhavedrivenatleast100yardsorsothenpullinto
yourdrivewayoranyotherflatandhopefullylevelspot,slowlywithoutusingmuch,ifanybrakessoasnottocausethefronttodipdownforthemeasurement.STAYINTHECARFORGROUNDCLEARNACEMEASUREMENTS.Havesomeoneelsegrabyourtapemeasure.ChecktherearoftheRZRbymeasuringfromthebottomoftheframetotheground,inthecenterofthechassisattherear.Thisshouldbeabout12”offtheground.Nowmeasurethefrontatthebottomoftheframejustbehindthelowercontrolarm
mountandforwardofthefirewall.Thisshouldbe12.5”to13”offtheground.ThefrontshouldbehigherbecausewewanttheRZRtobelevelorabithigherthantherearwithyouaresittinginit.Thismeansitwillbeaninchto.5”higherthantherearwhenempty.
Seethepicturesaboveandontherighttomakesureyouaremeasuringinthecorrectspots.
IfyourRZRissittingtoolowortoohighthenjackitupandadjustthepreloadcollaraccordingly.Youcanoftenspinthecollarbyhandjustbygrabbingthespringsandtwistingthemandthecollartogether.IfyouhaveFoxshocksthenuseastandardscrewdrivertounlockthetwopreloadcollarsandspinthemupordownaccording.WithWalkershocksyoucanuseanextensioninthepre-loadcollarholestospinthem.Anyadjustmenttothecollarwillchangetherideheightaboutdoubletheamountyoumovethecollar.Forinstance,ifyoumovethepreloadcollardown½”itwillraisetheRZRabout1”.YourspringsareNEWandtheywillsettleabitwithuse.Afterabout200milestheywillbewheretheyliketobepermanently.Pleasecheckyourrideheightataround100andagainat200milesandmakemorepreloadadjustmentsasneeded.NeverraiseorlowertheRZRtomakethesuspensionstifferorlooser!Thespring’sjobistoholditup.Allothertuningisdonewiththecompressionadjustorontheshockorthe“Silent”crossoverringsinsidetheuppercoilspring.Nowthatyouhavetherideheightdialedinletsgothroughtheshocktuningprocedure.
Ourgoalwithyournewsetupistogetthesoftest,mostplushridethroughallterrainaspossiblesothatyoudon’tfeelthebumps,rocks,tracks,ect.Forthisreasonstartwithallofthecompressionadjustersallthewaylooseorcounterclockwise.Thiswillbeyoursoftestride.OnaWalkershocktheadjusterisalargeknobonthereservoiroftheshockyoucanturnbyhand.OnaFoxshocktheadjustercanbeablueplasticknoboritcanbeasmalladjusterthatrequiresastandardscrewdrivertomoveit.NowpickyourfavoritetrailanddrivetheRZRlikeyounormallydo.Ifitdoesn’tbottomoutonthebighitsorGoutsthengreat,leaveitwhereitis!Butifyoubottomoutthefront6or7timesina30minuteblastthenyouneedtoaddsomecompressiontotheshock.Turnthecompressionadjuster2-3clicksstifferwhichisclockwise.Onlyadjustthefront.Thereisnoreasontostiffenupthebackifthefrontisbottoming.Nowrunthesametrailagainandifthebottominghasstoppedthenyouaredone!Ifitstillbottomsoutabitthenadd2-3clicksofcompressionuntilitstops.Samegoesfortherearifitistheonethatbottomsoutthemost.Justadd2-3clicksof
compressionontheadjusteruntilitstops.NowifyoubottomouttheRZR1timeinanhourridewewouldcallthatperfect.Anythingcanbebottomedoutifyoumakeabigmistake.Atleastyouknowwherethelimitisandtherideisasplushandsmoothasitcanbefor99%ofeverythingyoudo.
Forthemoreadvancedsuspensiontuners,youcanplaywiththe“silent”crossoverringsaswell.Theycontrolwhen,thoughcompressingyoursuspension,theheavierlowerspringcomesintoplayandmakesyoursuspensionconsiderablystiffer.Wesetthecollarslocationatanall-around,greatplacethatwehavefoundthroughtesting.But,youcanadjustittosuityourdrivingstyletoo.Thehigheruptheshockyourunthecollarthelongerthesuspensionwillremainsoftandplush.Thenegativetothisisthatthehigheruptheshockyourunthecollarthemorebodyrollyouwillget,themorefrontdiveorrearsquatyouwillgetandthelesshelpinthebumpstageorbighitsyouwillget.Theloweryourunthecollarthequickerthesuspensionwillmovefromsofttostiff.Theadvantagetothisislessfrontdiveorrearsquat,lessbodyrollandmorehelpinthebighitswithoutturningupthecompressionknobontheshocks.Thismaybeaperfectthingifyouareracingshortcourse.Thenegativetothisisthattheplushridewillgoawayveryquicklyandthechatterandstiffnesswillstarttocreepbackintoyourseatsoon.Don’tworry,alloftheseadjustmentscanalwaysgobacktowhereyoustartedjustbymovingthemback.Feelfreetoexperimentandseewhatyoulikeordislike.Finally,moreweightwillmaketheRZRbottomoutsoonersoexperimentwithyourshockadjusterstoaccommodateformorepassengers.Asaruleofthumb,weadd2-3clicksofcompressiontothefrontifyouadda180lbpassenger.Ifyouhavea4seaterthenyoumayadd1-2clickstotherearshocksforonerearpassengerand2-3clicksfortworearpassengers.Thesesettingsshouldcompensatefortheaddedweightsoyoucankeepyourspeedsthesameasyouwouldbyyourself.
Thecrossoverringsaredesignedtoberubbedbythecoilsprings.Asthespringcompressesitvibratessidetosideandcanrubthecrossoverring.Thisisnormal.Sometimesthespringsdon’tsitperfectlyflatontheplasticdivider.Youwillnoticethisbylookingattheplasticspringdividerwhenthecarisontheground.Ifitisfairlystraightwiththeshockbodyyourgoodtogo.Butifitis
sittingsidewaysabitthenyoucanclockthespringsdifferentlytohelpthis.Jackthecarupandclocktheupperandlowersprings90degreesapartfromeachotherbytwistingthembyhandinsteadof180degreesapart.Thismaygetthedividertositstraighterandallowtheupperspringtorubthecrossoverringless.
That’sit.YouarenowallsettorunandadjustyourRZRlikeapro!Experimenttotrythingsandseewhatyouprefer.Rememberjustputeverythingbacktofullsoft,andstartoverifyouloseyourwayontheadjustments.Wehopethiskithelpstomakeyouthefastestandsmoothestpersoninyourgroup.Nowgoshowoffandhavefun!Thankyou.
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