DragonFire

DragonFire Racing3191 N Washington St. Suite 2Chandler, AZ 852251 (800) 708-9803http://www.DragonFireRacing.com

Suspension Kit for Polaris RZR XP1K Turbo-FOX ShocksPart # 16-1105 Polaris RZR XP1K Turbo-FOX Shocks

Congratulations on buying the Dragonfire Stage 3 Spring Kit for your Polaris RZR. This kit is the most complete kit available for the Polaris RZR and designed to be easily installed in your home garage with common hand tools. Be sure to check out the full line of

DragonFire Accessories for your vehicle at your local authorized dealer or online at http://www.DragonFireRacing.comDisclaimer

Off road activities can be hazardous and could lead to injury, dismemberment, paralysis and death. No warranty of representation is made as to the products ability to protect the user from any injury or death. The user assumes that risk. The acceptance and /or use of this merchandise purchased from DragonFire by the customer hereby shall release DragonFire from any and all liability pertaining to the use of such merchandise.

• Read and understand these instructions before installing product• This product does not provide roll over protection• Ensure doors are securely latched and locked prior to operating vehicle• Check all hardware before use• Improper installation may result in product malfunction• Improper installation may result in damage to vehicle• Do not use product if there are any signs of damage• Installation and inspection by a certified mechanic is recommended

Tools RequiredFloor JackJack Stand10mm Wrench14mm Wrench17mm Wrench19mm Wrench4mm Allen Wrench1/4” Allen WrenchFlat Screw DriverTape MeasureHammer & Chisel Tool (Non-Sharp)Plastic, Aluminum, or Wood piecePerch Adjustment Tool (included w/ product)

Pre-installation: Lay out components and compare to list and images.

Part & Hardware ListITEM QTY SIZE LENGTH TYPE

P1 2 3.75” 18” Lower Spring - RearP2 2 3.75” 8” Upper Spring - RearP3 2 3.0” 10” Lower Spring - FrontP4 2 3.0” 6” Upper Spring - FrontP5 6 3.75” - Spring Adapter (Guide)P6 4 3.0” - Stop RingP7 4 2.5” - Crossover RingP8 2 3.0” - Upper Split Spring PerchP9 2 2.5” - Upper Split Spring PerchP10 1 - - Perch Tool

P1

P2Optional ToolsBench ViseSpring CompressorSpanner Wrench

P3

P4

P5P6

P8

P9P10P7

DragonFire

Step 1: Place vehicle on a flat and level surface. Place gear selector in “Park”. Remove keys from ignition.

Front Shocks

Step 2: Measure ride height at front of vehicle, in center of frame (Figure A). Record it below.

Step 3: Measure ride height at rear of vehicle, in center of frame (Figure B). Record it below.

Record Ride Height:

Front ride height:________. Rear ride height:________.

Step 4: Jack front of vehicle upward until wheels are just off of the ground (Figure C) and place on Jack stands for safety.

Step 5: Uninstall the upper & lower bolts holding the shock per manufacturer’s service manual (Figure D).

Step 6: Remove shock from vehicle and clean shocks (Figure E). Repeat for opposite side.

Note: Shock Must Be Clean! Remove all dirt, grease, oil, sand, and other debris.

Step 7: Slide rubber bump stop 2-3” from original position toward center of shaft (Figure E - Arrow 1).

Step 8: Use spring compressor if it is available to remove factory spring. If it is not available, loosen adjusting nuts (Figure E - Arrow 3) with spanner wrench (or chisel and hammer to break loose), until able to remove lower spring perch.

Step 9: With spring removed, place shock upside down in a soft jaw bench vise. (The upper eyelet that is connected to the Reservoir body.)

Step 10: Be Careful - Do not damage shock body! Use piece of plastic, aluminum, or wood and hammer and knock lower plastic body slide protector upward off shock body. One good quick hit usually knocks it loose/off (Figure E - Arrow 2).

1

2

3

DragonFire

Step 11: Remove factory upper spring perches.

With spring compressor: Thread on new Dragonfire Perch [P9] using included perch adjustment tool. Ensure the DragonFire logo is upside down. Thread perch to 2-3/4” to where spring sits from start of shock body (Figure F*). Tighten Allen bolts to lock in place. Continue on Step 12.

With no spring compressor: Thread on new DragonFire Perch [P9] until it is near the bottom of thread and then continue on Step 12. (The perch will be adjusted to 2-3/4” after all springs & crossovers are installed.)

Step 12: Thread 2 crossover rings [P7] down shock body until top of crossover is 5-1/4” from start of shock body (Figure G*). Make sure crossover rings are installed with DragonFire upside down; therefore, when shock is flipped upright, the DragonFire logo will be right side up.

Step 13: Lock crossover rings together with chisel and hammer or proper spanner wrench (Figure H).

* Pictures are for Reference of how to measure; written dimensions are recommended.

Step 14: Install upper 6” spring [P4] and then install factory coil spring slider upside down or small end down. Ensure the logo is upside down so when shock is installed right side up the label will be correct (Figure I**).

Step 15: Install lower 10” spring [P3] upside down (Figure J).

Step 16: Install factory lower perch. Ensure the lower perch gap with gap 180° from coil end (opening facing the opposite side of coil end) (Figure K**).

With no spring compressor: Rotate adjusting perch until there is enough clearance between spring and shock lower eyelet to install lower perch, then rotate upper perch back to 2-3/4” with included perch adjustment tool. Lock into position by tightening ¼” Allen bolt (See Figure F).

** Pictures are for Reference Only - may or may not represent actual look of parts.

Step 17: Repeat Step 7 to 16 for the other front shock.

DragonFire

Step 18: Reinstall shocks back onto the vehicle per manufacturer’s service manual (Figure L).

Note for shock with rebound adjuster: For easy access to the rebound adjuster, have it face toward front of vehicle. To protect the rebound adjuster, have it face toward the rear of vehicle.

Step 19: Lower vehicle back onto the ground and shift gear to “Neutral”. Roll car forward and backward while bouncing up and down to let suspension settle.

Step 20: Repeat Step 1 to 3 to check ride height.

The front ride height should be 1/2” to 1” higher than the rear ride height.

Refer to your initial ride height numbers from above. Adjust your preload up or down to match your initial ride height numbers from above.

Rear Shocks

Step 21: Repeat Step 1 to 3.

Record Ride Height:

Front ride height:________. Rear ride height:________.

Step 22: Jack rear of vehicle upward until wheels are just off of the ground. Place on Jack stands for safety and then remove rear wheels.

Step 23: Remove bolt from upper rear a-arm/rear spindle. Remove bolts from shocks using wrenches and then remove from vehicle.

Note: Shock Must Be Clean! Remove all dirt, grease, oil, sand, and other debris.

Step 24: Repeat Step 7 to 10.

Step 25: Remove factory upper spring perches.

With spring compressor: Thread on new DragonFire Perch [P8] using included perch adjustment tool. Ensure the DragonFire logo is upside down. Thread perch to 2” to where spring sits from start of shock body (Figure I). Tighten Allen bolts to lock in place. Go to Step 26.

With no spring compressor: Thread on new DragonFire Perch [P8] until it is near the bottom of thread and then continue on Step 26. (The perch will be adjusted to 2” after all springs & crossovers are installed.)

Step 26: Thread 2 stop rings [P6] down shock body until top of stop ring is 8” from start of shock body. Make sure stop rings are installed with DragonFire upside down, therefore when flip shock upright the DragonFire logo will be right side up.

Step 27: Lock stop rings together with chisel and hammer or proper spanner wrench.

Step 28: Install in the following order: upper 8” spring [P2], provided spring guide [P5], factory coil spring slider upside down or small end down, and another spring guide [P5]. Ensure the logo is upside down so when shock is installed right side up the label will be correct.

Step 29: Install lower 18” spring [P1] with logo upside down and provided spring guide.

Step 30: Install factory lower spring perch, with gap 180° from coil end (opening facing the opposite side of the coil end).

With no spring compressor: Rotate adjusting perch until there is enough clearance between spring and shock lower eyelet to install lower perch, then rotate perch back to 2” with included perch adjustment tool. Lock into position by tightening ¼” Allen bolt.

DragonFire

Step 31: Repeat previous steps for the other rear shock.

Step 32: Reinstall shocks back onto the vehicle and then reinstall A-Arms/Spindle bolts. Torque to factory specifications. Then reinstall rear wheels and torque to factory specifications.

Note: For easy access to the rebound adjuster, have it face toward rear of vehicle.

Step 33: Lower vehicle back onto the ground, remove parking brake and take out of gear. Roll car forward and backward while bouncing up and down to let suspension settle.

Step 34: Repeat Step 1 to 3 to check ride height.

The front ride height should be 1/2” to 1” higher than the rear ride height.

Refer to your initial ride height numbers from above. Adjust your preload up or down to match your initial ride height numbers from above.

Tuning Note:

Dragonfire recommends a Front ride height of 13 ¼ “ to 13 ¾ ”and a Rear ride height of 12 ½” to 13” with 29” tires for desert/ rocky trail riding. You can adjust the ride height for your tire size and riding area as you prefer. Note: for every 1” reduction in tire size, lower ride height by ½”: for every 1” increase in tire size raise ride height by ½”. The initial settings should put you in the ball park for a car with bumpers, cooler and a spare tire installed. Some small adjustments of preload may be necessary to achieve your desired ride height. This can vary depending on accessories added or removed from car. Adjust preload to suite your personal preference.

The crossover stop rings can also be adjusted to allow your car to have a softer initial ride quality with slight more body roll, or a stiffer quicker ride, with less body roll. Move the crossover rings upward to increase gap between plastic spring divider and crossover stop rings to increase small bump suppleness. Lower the crossovers, decreasing gap, to decrease body roll. The adjustment from above, seem to be the best compromise of initial softness and minimal body roll. The crossovers can be adjusted to suite your personal preference.

Front shock settings:

Rebound Adjuster: Turn full in (clockwise - 30 clicks total) then back out (counter-clockwise) 10 clicks from full. (Use a flat blade screw driver)

Low speed compression (LSC): Turn full in (clockwise - 4 turns total) then back out (counter-clockwise) 3 turns from full. (Use a flat blade screw driver)

High speed compression (HSC): Turn full in (clockwise - 4 turns total) then back out (counter-clockwise) 3 ½ turns from full. (Use a wrench)

1 turn = 360°

Rear shock settings:

Rebound Adjuster: Turn full in (clockwise) then back out (counter-clockwise) 8 clicks from full. (Use a flat blade screw driver)

Low speed compression (LSC): Turn full in (clockwise - 4 turns total) then back out (counter-clockwise) 3 ½ turns from full. (Use a flat blade screw driver)

High speed compression (HSC): Turn full in (clockwise - 4 turns total) then back out (counter-clockwise) 3 ½ turns from full. (Use a wrench)

Your suspension should bottom out once or twice per ride, but not too harsh. If you are bottoming too much turn LSC and HSC inward ½ turn at a time until ride quality is achieved. If your ride is still too stiff, turn LSC and HSC outward ½ turn at a time and see if your results improve.

LSC adjusts low shaft speeds (NOT Vehicle Speed): whoops, jumps, rolling bumps

HSC adjusts fast shaft speeds (NOT Vehicle Speed): sharp square edged bumps, rocks, roots, potholes.

Adjust as necessary to achieve your ideal ride.

Check all fasteners after first ride and periodically for any loosening.

Time to ride and enjoy your smoother Polaris RZR.

For further assistance please contact us at customerservice@dragonfireracing.com or 1-800-708-9803.