Fox RZR XP1000 User manual

2.5 PODIUM-X
AFTERMARKET SHOCK
OWNER’S MANUAL
PODIUM RC2
RZR XP1000
OWNER’S MANUAL

Reference print standards 604-00-300 rev
A 605-01-108 rev B Pg. 2
CONTENTS
CONGRATULATIONS .............................................................................................. 3
CONSUMER SAFETY .............................................................................................. 3
UNDERSTANDING THE PODIUM RC2 .................................................................... 4
INSTALLING YOUR SHOCKS .................................................................................. 5
READING THE SPRING RATE ................................................................................ 7
SETTING THE RIDE HEIGHT .................................................................................. 7
ADJUSTING SPRING CROSS OVER ...................................................................... 8
DUAL SPEED COMPRESSION (DSC) ................................................................... 11
REBOUND ADJUST ............................................................................................... 12
MAINTENANCE ...................................................................................................... 12
REBUILD / SERVICE .............................................................................................. 13
WARRANTY ............................................................................................................ 13
SERVICE ................................................................................................................ 13

605-01-108 rev B Pg. 3
CONGRATULATIONS
Thank you for choosing FOX Podium shock absorbers for your UTV. In doing so, we believe that you have
chosen the finest suspension products in the world.
FOX shocks have been designed, tested and manufactured in the USA for more than 35 years.
As a consumer and supporter of FOX products, you need to be aware of the importance of setting up your
shocks correctly to ensure maximum performance. This manual provides step-by-step instructions on how
to set-up and maintain your shocks. It is a good idea to keep your proof of purchase with this manual and
refer to it for service and warranty issues.
This manual does not contain step-by-step shock rebuild instructions. Rebuilding should be carried out by
an authorized FOX service technician.
CONSUMER SAFETY
WARNING: Driving a UTV can be dangerous and can result in death or serious injury.
Take your responsibility for yourself and others seriously, and read the following safety tips:
- Keep your vehicle and its suspension systems in optimal working condition.
- Always wear protective clothing, eye protection and a helmet.
- Know your limits and drive within them!
The FOX coil-over shock contains a high pressure nitrogen charge. The shock should only be opened by
an authorized FOX technician.
WARNING: Opening a nitrogen pressurized shock can be dangerous and can result in SERIOUS
INJURY OR DEATH. NEVER attempt to disassemble the damper of your coil-over shock. Do not
puncture or incinerate the shock absorber or damper portion. Always wear eye protection when installing
or adjusting your shock absorber

APPLICATIONS Dunes / Race and
Trail 605-01-108 rev B Pg. 4
UNDERSTANDING THE PODIUM RC2
•Body
!Large diameter 6061-T6 smooth bore seamless aluminum body allows for greater damping force
capability while allowing the shock to run at lower overall temperatures.
!Increased oil volume allows for reduced fade and increased durability.
!Genuine Kashima Coating for less friction and reduced heat.
•Spring Adjustment
oPreload adjustment
oCrossover ring adjustment
•High-Speed Compression Adjuster (22 position)
oThe high-speed compression (HSC) adjuster mainly affects compression damping
during medium-to-fast suspension movements such as steep jump faces, harsh flat
landings and aggressive whoops. The goal is to run as little high-speed compression
damping as possible without bottoming.
•Low-Speed Compression Adjuster (24 position)
oThe low-speed compression (LSC) adjuster primarily affects compression damping
during slow suspension movements such as G-outs or smooth jump landings. It also
affects wheel traction and the harshness or plushness of the vehicle (note that low-
speed has nothing to do with the speed of the vehicle). Choose an LSC setting that
gives good body control without causing excessive harshness or loss of traction.
•Rebound damping Adjustment (22 position)
oRebound damping controls the rate at which the shock returns after it has been compressed.
The proper rebound setting is a personal preference and changes with rider weight, riding style and
conditions.
•Teflon-Lined, Heat-Treated, Alloy Steel Spherical Bearings
•Hard-Chrome-Plated Alloy Steel Shaft
•Bottom-Out Control Technology:
oBottom-out cup provides additional end-of-stroke compression damping for those really
hard hits.
!Offers up to 30 percent more damping at the final 25 percent of travel.
This allows the shocks to be tuned to give improved small- bump compliance in the upper
portion of the stroke while still maintaining the ability to absorb huge impacts effectively.

605-01-108 rev B Pg. 5
INSTALLINGYOURSHOCKS
Your shock absorber should come supplied with the correct reducers pre-installed to mount the shock to
your vehicle.
WARNING: Contact FOX if these reducers do not fit correctly. Correct shock mounting is critical for correct
operation and for your safety.
Front Shocks:
•Raise the front of the vehicle with a jack, support with jack stands and remove the stock shock
absorbers. Document the reservoir orientation so the FOX replacement shocks mount in a similar
manner so reservoirs are oriented toward the rear of the vehicle.
•Install the upper mounting bolt through the shock eyelet and upper suspension mount.
•Install the lower mounting bolt through the shock eyelet and lower suspension mount.
•Tighten the upper and lower shock bolts. Follow the Manufacturer’s recommended torque specifications.
•After shocks have been tightened to the torque spec as listed, remove the jack stands and lower the
vehicle.
Rear Shocks:
•Raise the rear of the vehicle with a jack, support with jack stands and remove the stock shock
absorbers along with the reservoir hose clamps and isolators.
•In order to mount the FOX shocks, the plastic cover that goes around the stock shock hose will need to
be removed and stored, as it will not be needed.
•Install the upper mounting bolt through the shock eyelet and upper suspension mount.
•Install the lower mounting bolt through the shock eyelet and lower suspension mount.
•Tighten the upper and lower shock bolts. Follow the Manufacturer’s recommended torque specifications.
•Maneuver the reservoir and hose through the opening left by the cover that had been removed.
•Position the reservoir as shown and install the clamp cover and qty. 4 ¼-20 X 1.5” socket head cap
screws. Tighten in a crisscross pattern and torque to 15 ft-lbs. be sure to use blue Loctite® 242 to
ensure screws do not come loose.
•After shocks have been tightened to the torque spec as listed, remove the jack stands and lower the
vehicle.

605-01-108 rev B Pg. 6
Checking the Ride height
•Once the vehicle is on the ground, the scrub needs to be taken out of the tires so the ride height can be
measured. In order to remove the scrub the vehicle needs to be driven at least 10 feet.
Measure the front and rear ride heights as shown on a flat and level surface.
FRONT
The FRONT should always be set about ½" higher than the REAR.
REAR
Increase spring preload to increase vehicle ride height.
WARNING: Be sure not to add too much pre-load into the coil spring. Doing so may result in coil-bind, leading
to spring failure and potentially injury or death. If you are at maximum preload and need more ride-height,
contact FOX for a stiffer spring.
•The distance from the ground to the front outer frame rail should be between 13.5-13.75”
•The distance from the ground to the rear frame rail should be between 13.25-13.5”
The optimum vehicle ride height will be determined by exact vehicle configuration and usage.
Individual vehicles can vary significantly in weight so it is important to check the ride height when you first
install your shocks. For example, if you have added accessories to your vehicle that increase the weight, you
may need to consider alternate spring rates.

605-01-108 rev BPg. 7
READING THE SPRING RATE
FOX coil-over shocks only use quality, high stress race springs. The springs are a shot-peened, heat-treated
chrome-silicon material, designed to give maximum travel and minimum weight. They are preset to ensure
they don’t sag over time.
TIP: The springs are typically labeled: XXXX-
XXX-XXXX
For example: 1000-250-0225
The first four digits indicate the spring free length: 1000 = 10.00 inches
The middle three digits indicate the spring free internal diameter: 250 = 2.50 inches The last four digits
indicate the spring rate: 0225 = 225 lb-in
SETTING THE RIDE HEIGHT
All FOX coil-over piggyback shocks feature adjustable spring preload. Your vehicle performance is sensitive
to ride height variations.
P/N 398-00-393
WARNING: Do not add excessive amounts of preload into the coil spring. Doing so may result in coil-bind,
which could lead to spring failure and potential injury or death. To check coil-bind, put several zip-ties around
individual coils. If they break or show contact, there is excessive preload. If you are at maximum preload and
need more ride height, contact FOX for a stiffer spring.

605-01-108 rev B Pg. 8
ADJUSTING SPRING CROSSOVER (DUAL SPRING ONLY)
The spring crossover point is an important tuning parameter. A softer initial spring rate
offers improved traction and hook-up while a higher spring rate deep into travel helps to resist bottoming on
jump landings.
As a rough guideline, the spring crossover point should be as deep into travel as possible without
experiencing excessive bottoming. The crossover point is defined as a percentage of the total shock travel.
The factory setting for the spring crossover point is 55 percent. This means that a 5-inch travel shock would
have the crossover point at 2.75 inches (5.0 inches x 0.55) into the shock travel.
In order to calculate your spring crossover ring placement, you need to know four important pieces of
information:
1. Metal-to-metalshocktravelininches(measurebeforespringinstallation).
2. Main spring rate (lb-in) - marked on spring (see Reading the Spring Rate).
3. Tender spring rate (lb-in) - marked on spring (see Reading the Spring Rate).
4. Desired crossover point (as a percentage).
The shock travel is the exposed length of the shaft (including the bump stop) when the shock is fully
extended. It may be easiest to measure before you install the shock.
Some shocks use external spacers below the bump stop to limit travel. Do not include the spacer length as
part of the travel.
The crossover point is a tunable parameter. It should be between 45 and 65 percent.
SETTING THE CROSSOVER POINT (shock has been removed from vehicle for display purposes)
NOTE: ALWAYS W EAR EYE PROTECTION W HEN WORKING WITH SHOCK ABSORBERS.
STEP 1 Set ride height as described on page five.
STEP 2 Once you have established the correct preload, jack up the UTV and place on a stand to keep the
wheel off the ground. The shock should be fully extended.
SHOCK TRAVEL

605-01-108 rev B Pg. 9
STEP 3 Use a hammer and flat blade screwdriver, to loosen the crossover rings.
STEP 4 Determine the Spring Correction Factor using the following table:
STEP 5 Use the following formula to calculate crossover ring placement:
Crossover Ring Placement = Shaft Travel (in.) x Crossover Point x Spring Correction Factor
EXAMPLE
•
A 5.2-inch travel shock with a 225 lb-in main spring and an 800 lb-in tender spring.
•
The crossover point is set at 55 percent.
•
From the table above, the spring correction factor is 0.220.
•
From the above formula, the crossover ring placement value is 5.2 x 0.55
x 0.220 = 0.629 inches.
IN THE ABOVE EXAMPLE, 55 PERCENT IS WRITTEN AS 0.55.

605-01-108 rev B Pg. 10
Crossover ring
placement
value should
match the
distance from
the top of the
spring
coupler
to the bottom of
the crossover
ring. Example
.629 inches
You may need a small, flexible ruler or measuring device to accurately determine the crossover ring location.
Another useful way of measuring is to count the threads on the body (the thread pitch on the body is 14
threads per inch). If you know the crossover ring location, multiply by 14 to get the number of threads
between the spring coupler and crossover ring. In the example above, 0.629 inches = 0.629 x 14 = 8.8
threads.
Changing the spring preload, tender or main spring free-length or rate will mean that you need to reset
the crossover ring placement.
STEP 6 Adjust the crossover (as shown on the previous page) so that its distance from the spring coupler is
equal to the crossover ring placement value calculated in Step 5. Lock the crossover rings together
once complete with flat-bladed screwdriver and hammer.
STEP 7 Remove the UTV from the stand.
.629”