Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00. Fax +46 8 590 025 80.
www.ohlins.com
PB 532, issued 2006 01 04
Mounting Instructions
Öhlins shock absorber kit PB 532
for Polaris IQ 440 - rear
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Kit Contents
Before installing the shock absorber, please
check the contents of the kit. If anything is
missing, please contact your Öhlins dealer.
Shock absorber 36 PRXW PB 532 (1)
Ball joint spacer 10x30 00118-11 (2)
Ball joint spacer 10x32 00118-13 (2)
O-ring 00338-06 (2)
Sticker Öhlins 00197-01 (2)
Sticker memo notes 01180-01 (1)
Owner’s manual (1)
Before Installing
Öhlins Racing AB cannot be held responsible
for any damage to shock absorber or vehicle,
or injury to persons, if the instructions for fi tting
and main tenance are not followed exactly.
Similarly, the warranty will become null and
void if the instructions are not adhered to.
Öhlins products are subject to continuous
improvement and development. Conse-
quently, although these instructions include
the most up-to-date information available
at the time of printing, there may be minor
differences between your shock absorber
and this manual. Please consult your Öhlins
dealer if you have any questions regarding
the contents of this manual.
Compression damping adjuster:
Adjustments are made on top of the reservoir.
Low speed adjustments: Slotted centre screw.
High speed adjustments: Hexagon screw.
Rebound damping adjuster:
Adjust by turning the screw above the end eye
bracket. Use an ordinary coin or likewise.
NOTE!
When delivered the Öhlins shock absorber is
dialed to recommended settings for the spe-
cifi c brand and make of the snowmobile. If you
have changed the setting, reset according to
the following:
The adjusters have a normal right hand thread.
Turn clockwise to fully closed. Turn counter
clockwise to open and count the clicks until you
reach the recommended number. See Setup
data below.
CAUTION!
Do not use too much force, delicate sealing sur-
faces can be damaged. Do use fi ngers only.
Rebound
adjuster
Low speed
compression
adjustment
High speed
compression
adjustment
Adjustments
Shock absorber length 382 mm
Shock absorber stroke 129 mm
Low speed comp. damping 15 clicks
High speed comp. damping 2 turns
Rebound damping adj. 8 clicks
Setup data
Read more about settings and adjustments
in your Öhlins Owner’s manual.
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+
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WARNING!
1. Installing a shock absorber, that is not
approved by the vehicle manufacturer, may
affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage that may oc-
cur after fi tting the shock absorber. Contact
an Öhlins dealer or other qualifi ed person
for advice.
2. Please study and make certain that you fully
understand all the mounting instructions and
the owner’s manual before handling this shock
absorber kit. If you have any questions regard-
ing proper installation procedures, contact an
Öhlins dealer or other qualifi ed person.
3. The vehicle service manual must be
referred to when installing the Öhlins shock
absorber
!
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out in-
side the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
shock absorber.
Safety Signals
Important information concerning safety is
distinguished in this manual by the following
notations:
The Safety alert symbol means:
Attention! Your safety is involved.
WARNING!
Failure to follow these warning instruc-
tions could result in severe or fatal
injury to anyone working with, inspect-
ing or using the shock absorber, or to
bystanders.
CAUTION!
Caution indicates that special pre-
cautions must be taken to avoid damage
to the shock absorber.
NOTE!
Indicates information that is of importance
regarding mounting procedures.
!
!
Mounting instructions
WARNING!
1. It is advisable to have an Öhlins dealer
or other qualifi ed person install the shock
absorber.
2. Follow the instructions in the vehicle service
manual when changing the shock absorber.
3. When working on a raised vehicle, make
sure that it is securely supported to prevent
it from falling.
!
1
Raise the rear end of the snowmobile. Make
sure that it is securely supported so that it
will not fall over.
2
Remove the attachments holding the front and
rear swing arms to the snowmobile, two screws
on each side.
3
Remove the rear suspension from the track.
4
Release the spring preload of the rear suspen-
sion by removing the pin. Hold the spring in
a fi rm grip and release the spring carefully.
We advise you to have an assistant for this
procedure.
WARNING!
The springs are heavily preloaded. It is very
important to hold the spring in a firm grip
when removing the attachment. Use protec-
tion gloves.
5
Loosen the rear attachment of the original shock
absorber.
NOTE!
If the screw is hard to reach, loosen the limiter
strap and move the swing arm to reach the
screw.
6
Loosen the front attachment of the original
shock absorber. Remove the collar. You will
need it for the Öhlins shock absorber.
7
Measure the rear bracket width of the original
shock absorber. Install the correct spacers and
o-rings to the bracket.
Width = 30 mm, Install: Spacers 00118-11
O-rings 00338-06
Width = 32 mm, Install: Spacers 00118-13
O-rings 00338-06
8
Cut the collar and fi t it into the front bracket.
Remove the middle part, it cannot be fi tted into
the Öhlins shock absorber. See fi gure below.
9
Install the Öhlins shock absorber with the res-
ervoir downwards. Fasten the front attachment.
Use the original screw, washers, nut and the
piece of the collar, from step 7.
NOTE!
The rebound adjuster screw should be facing
upwards.
10
Fasten the rear attachment, spacers and
o–rings. Use the original screw and nut.
11
Reattach the spring preload of the rear suspen-
sion. See step 4.
12
Put the rear suspension back into the track.
Tighten the screws, two on each side of the
vehicle. See step 2.
NOTE!
Make sure that all screws are tightened to the
correct torque and that nothing fouls or re-
stricts movement of the shock absorber when
the suspension is being fully compressed or
extended.
13
Read more about the Öhlins shock absorber in
the Öhlins owners manual.
1
!
2
3
original
collar
cut
Öhlins shock absorber
original
screw
original nut
original
washers
Reservoir
downwards
Rebound
adjuster
upwards
!
8
9
Front
attachment
Remove the
pin
4
!
remove
17.3 mm
17.3 mm
NOTE!
spacer
spacer
o-ring
o-ring
7
Rear attachment
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1
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2
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