WP DYNAMICS K25-PL1005-17 XP 1000 Stage 1 Dual Rate Springs User Manual

K25-PL1005-17 XP 1000 Stage 1 Dual Rate Springs

Product Information: K25-PL1005-17 XP 1000 & XP Turbo Walker Evans Needle

Shocks 14-21

The K25-PL1005-17 XP 1000 & XP Turbo Walker Evans Needle Shocks 14-21 is a suspension system or component that enhances the on and off-road performance of your vehicle. This product comes with limited lifetime warranty and requires constant maintenance to keep your vehicle safe. The package includes Front Tender Springs (2), Front Main Springs (2), Front Spring Dividers (2), Rear Tender Springs (2), Rear Main Springs (2), and Rear Crossover Rings (2).

Product Usage Instructions
Before using the K25-PL1005-17 XP 1000 & XP Turbo Walker Evans Needle Shocks 14-21, please read and follow the instructions carefully to ensure proper installation and avoid injury or death.

Step 1 – Safety Warning:
Do not operate your vehicle under the influence of alcohol or drugs. Always operate your vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Failure to drive safely may result in serious injury or death to driver and passengers. Thoroughly inspect your vehicle before and after every off-road use. Check the surrounding area for obstructions, people, and animals before moving the vehicle. All raised vehicles have increased blind spots; damage, injury and/or death can occur if these instructions are not followed.

Step 2 – Installation Warning:
All steps and procedures described in these instructions were performed while the vehicle was properly supported on a two post vehicle lift with safety jacks. Use caution during all disassembly and assembly steps to insure suspension components are not over extended causing damage to any vehicle components and parts included in this kit.

Step 3 – Tools Required:

• Ratchet (1)
• 15mm Socket (1)
• 15mm End Wrench (1)
• 18mm Socket (1)
• 18mm End Wrench (1)
• 5/64 Allen Wrench (1)
• Spanner Wrench or 1/4 Punch (1)
• Tape Measure (1)

Step 4 – Parts Included:

• Front Tender Springs (2)
• Front Main Springs (2)
• Front Spring Dividers (2)
• Rear Tender Springs (2)
• Rear Main Springs (2)
• Rear Crossover Rings (2)

Step 5 – Installation:

Please follow the instructions carefully for proper installation of the K25-PL1005-17 XP 1000 & XP Turbo Walker Evans Needle Shocks 14-21.

1. Remove the stock shocks from the vehicle.
2. Install the Front Tender Springs onto the Front Main Springs using the Front Spring Dividers.
3. Install the Rear Tender Springs onto the Rear Main Springs using the Rear Crossover Rings.
4. Install the assembled Front and Rear Springs onto the vehicle using the provided tools.
5. Adjust the ride height of the vehicle using a tape measure and the provided tools.

If you have any questions or concerns about the installation process, please contact our customer service at PHONE: 435-753-7774 or EMAIL: customerservice@zbrozracing.com.

INTRODUCTION

PLEASE RETAIN THIS DOCUMENT FOR FUTURE REFERENCE

IF your ZBROZ® product has a damaged or missing part, please contact customer service directly and a new replacement part will be sent to you immediately.
For warranty issues, please return to the place of installation and contact ZBROZ®.

Business hours are Monday through Friday 8AM-5PM MST.
PHONE: 435-753-7774
EMAIL: customerservice@zbrozracing.com
WEBSITE : www.zbrozracing.com

LIMITED LIFETIME WARRANTY

ZBROZ® will warranty to the original purchaser any failed ZBROZ® suspension product in the event of failure due to construction or material failure of the product. You will be required to contact ZBROZ® customer service with descriptions and photos that resulted in failure.
ZBROZ® builds suspension products to meet and exceed your expectations in quality, performance and durability. All ZBROZ® suspension products are rigorously tested during development and prototype parts are pushed to the limit by professional industry athletes, backcountry athletes and race teams. ZBROZ® Limited Lifetime Warranty excludes the following wear parts as these parts are considered defective when worn: Ball Joints, Bushings, Bump Stops, Tie Rod Ends, Heim Joints, Shock Absorbers Product purchased directly from ZBROZ® has a 90 day return policy on uninstalled products from the date of purchase (may be subject to restocking fee). Uninstalled product returns must be in the original ZBROZ® packaging. Please call 435-753-7774 to get an RMA# for any return. Customer is responsible for shipping costs back to Zbroz Racing. Returns without RMA# will be refused. Contact ZBROZ® directly about any potentially defective parts prior to removal from vehicle.
ZBROZ® is NOT responsible for any subsequent damages to any related vehicle parts due to misuse, abuse, improper installation, or lack of maintenance. Furthermore, ZBROZ® reserves the right to change, modify or cancel this warranty without prior notice.

FOLLOW INSTRUCTIONS TO ENSURE PROPER INSTALLATION
READ INSTRUCTIONS THOROUGHLY AND COMPLETELY BEFORE BEGINNING INSTALLATION. INSTALLATION BY A CERTIFIED PROFESSIONAL MECHANIC IS HIGHLY RECOMMENDED. ZBROZ® IS NOT RESPONSIBLE FOR ANY DAMAGE OR FAILURE RESULTING FROM IMPROPER INSTALLATION.

TOOLS:

• Ratchet (1)
• 15mm Socket (1)
• 15mm End Wrench (1)
• 18mm Socket (1)
• 18mm End Wrench (1)
• 5/64 Allen Wrench (1)
• Spanner Wrench or 1/4″ Punch (1) Tape Measure (1)

PARTS:

• Front Tender Springs (2)
• Front Main Springs (2)
• Front Spring Dividers (2)
• Rear Tender Springs (2)
• Rear Main Springs (2)
• Rear Crossover Rings (2)

Step 1 — Safety Warning

• MISUSE OF THIS PRODUCT COULD LEAD TO INJURY OR DEATH. You should never operate your vehicle under the influence of alcohol or drugs. All raised vehicles have increased risk including blind spots; damage, injury and/or death can occur if these instructions are not followed.
• Suspension systems or components that enhance the on and off-road performance of your vehicle may cause it to handle differently than it did from the factory. Extreme care must be used to prevent loss of control or vehicle rollover during abrupt maneuvers.
• Always operate your vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Failure to drive safely may result in serious injury or death to driver and passengers. You should never operate your vehicle under the influence of alcohol or drugs.
• Driver and passengers must ALWAYS wear your seat belts, avoid quick sharp turns and other sudden maneuvers. ZBROZ® does not recommend the combined use of suspension lifts, body lifts, or other lifting devices.
• Constant maintenance is required to keep your vehicle safe. Thoroughly inspect your vehicle before and after every off-road use.
• It is the responsibility of the retailer and/or the installer to review all state and local laws, with the end user of this product, related to bumper height laws and the lifting of their vehicle before the purchase and installation of any ZBROZ® products.
• It is the responsibility of the driver to check their surrounding area for obstructions, people, and animals before moving the vehicle.
• All raised vehicles have increased blind spots; damage, injury and/or death can occur if these instructions are not followed.

Step 2 — Installation Warning

• All steps and procedures described in these instructions were performed while the vehicle was properly supported on a two post vehicle lift with safety jacks.
• Use caution during all disassembly and assembly steps to insure suspension components are not over extended causing damage to any vehicle components and parts included in this kit.
• Included instructions are guidelines only for recommended procedures and are not meant to be definitive. Installer is responsible to insure a safe and controllable vehicle after performing modifications.
• ZBROZ® recommends the use of an OE Service Manual for model/year of vehicle when disassembly and assembly of factory and related components.
• Unless otherwise specified, tighten all bolts and fasteners to standard torque specifications listed within the OE Service Manual.
• Suspension components that use rubber or urethane bushings should be tightened with the vehicle at normal ride height. This will prevent premature wear or failure of the bushing and maintain ride comfort.
• Larger tire and wheel combinations may increase leverage on suspension, steering, and related components.
• Due to payload options and initial ride height variances, the amount of lift is a base figure. Final ride height dimensions may vary in accordance to original vehicle ride height. Always measure the vehicle ride height prior to beginning installation.
• This spring kit can be installed with shocks on your “VEHICLE” by using a floor jack or lift. Select a flat install location. If using floor jack, always make sure to block tires – work safely! If removing shocks for installation. Back OEM Preload rings on all shocks before removing. Use a solid mounted vice for installation.
• FOLLOW THESE STEPS FIRST
  1. Measure current ride height at front center frame point and rear center frame point.
  2. Write down these measurements for before and after installation notes.
  3. If removing shocks, label each shock to eliminate installation problems with the piggyback reservoirs positioning/clocking when reinstalling.
  4. Clean shocks! Remove all dirt and mud.
  5. Lift vehicle using a floor jack or lift and remove tires.

Step 4 — Ride Height Warning

• Due to payload options and initial ride height variances, the amount of preload is a base figure. Final ride height dimensions may vary in accordance to original vehicle ride height. Always measure the vehicle ride height prior to beginning installation.

Step 5

• Before installing your new springs, be sure you are parked on a flat surface. Lift the rear of the RZR and remove the rear wheels and tires.
• IMAGE 1 : Before taking the lower shock bolt out, use spanner wrench or a punch to loosen the preload ring completely off of the springs. NOTE: A 1/4″ punch fits into the preload rings holes nicely.
• IMAGE 2: Now remove the lower shock bolt using the 18mm end
• NOTE: Once the is nut removed, you have may have to maneuver the hub up and down to remove the bolt.
• IMAGE 3 : Now that you have the lower shock mount free and the springs loose, use a flathead screwdriver to pry the bump stop up out of the way.

Step 6

• IMAGE 1: Once you have the bump stop out of the way, remove the lower
• IMAGE 2: With the spring retainer out of the way, remove the entire spring stack. Set the springs aside but hang on to the stock spring retainer as it will be reused in reassembly .
  IMAGE 3:  Now that the springs are off the shock, go ahead and place the crossover rings provided onto the shock body and secure using the 5/64 Allen bolts with a 3/32 allen wrench.
  NOTE: Do not tighten the crossover screws all the way yet. the crossover ring will have to be adjusted after the springs are in place and the preload is set.
  Be sure not to cross thread the crossover ring onto the shock body. It should spin freely. If it doesn’t, check for dirt and alignment on threads.

Step 7

• IMAGE 1: With the crossover ring in place, replace the spring stack with your new rear ZBROZ springs with the spring divider facing long side down as shown in the image.

• Replace the lower spring retainer and reassemble the lower shock mount and tighten the bolt back to the factory torque specifications.
  Due to an internal spring in the shock itself, preload must be set while putting downward pressure on the hub. If you do not keep constant downward pressure on the hub your preload and crossover settings will be incorrect resulting in poor ride height and ride quality.

• To set the preload, tighten the preload ring down until it is touching the springs. Once the preload ring is touching the springs, add 8 full rotations of preload to the spring stack. keep in mind this is a basic starting point, you may need to add more preload depending on the weight of your vehicle.
  NOTE: It is helpful to mark a line or and x on the preload ring to make it easier to count your rotations. SEE IMAGE 2

• IMAGE 3: Once your preload is set then the crossover can be set. Crossover settings in the rear should be 4.75″ This measurement should be taken from the bottom of the crossover ring to the top of the spring divider. Remember this is a starting point and more adjustment may be needed later.
  Once you have the preload and crossover in place you may now tighten the 4 allen screws holding the crossover ring in place using a 3/32 allen wrench. Repeat the above steps on the opposite side.

Step 8

• Move your jack to the front of the car and remove the With the wheels and tires out of the way, begin by loosening the preload completely off of the shock.

• NOTE: A 1/4″ punch works nicely if you cant spin it by hand.
  IMAGE 1 Once the preload is out of the spring stack go ahead and remove the lower shock mount bolt and the lower spring retainer.
  NOTE: You will have to use a flathead screwdriver to pry the bump stop out of the way like previously done on the rear shock.
  IMAGE 2 After you get the spring retainer out of the way, completely remove the spring stack off of the front shock.

• Set the stock springs and spring divider aside as they will not be used in reassembly.

Step 9

• IMAGE 1: When reassembling the new spring stack, the supplied spring divider will be placed long side facing up as shown in Images 1 & 2.

• IMAGE 2: Place the new spring stack back over the shock and install the new lower spring retainer provided in the kit. Then replace the lower shock mount bolt.

• Due to an internal spring in the shock itself, preload must be set while putting downward pressure on the hub. If you do not keep constant downward pressure on the hub your preload and crossover settings will be incorrect resulting in poor ride height and ride quality.

• Repeat the process used in the rear shocks to add preload to front shocks. Begin with 6 turns of preload as a starting point. depending on your vehicle more or less preload might be necessary.
  NOTE: You will not have to measure the crossover in the front shocks as the new spring divider provides the correct crossover setting.
  Be sure to tighten all hardware back to the factory torque specifications before lowering the vehicle.

• IMAGE 3: Now that you have your spring kit installed you can now go back and add the new decals provided for the shock reservoirs. It helps to remove old decals and clean shock reservoirs before installing new decals.

Step 10 — Check Ride Height Setup

• Drive your vehicle around at slow speed, turning left and right to settle the spring kit. Coast to stop, do not apply brakes to ensure spring kit is naturally settled. Measure and compare ride height measurements with pre-install measurements. Adjust by adding or removing Preload.
• How to Adjust: With tires on, use a floor jack or lift so that shocks are fully extended and adjust as follows:
• If Ride Height is too TALL: Rotate OEM Preload ring 2 full counterclockwise rotations, settle spring kit and check.
• If Ride Height is too LOW: Rotate OEM Preload ring 2 full clockwise rotations, settle spring kit and check.

Step 11 — Final Results

• Ride Height Gain: average ride height  increase is 2”.
• Aggressive Stance: allows fitment of larger tires.
• Tune-able Progressive Spring Setup: soaks up small bumps better before initiating main springs.
• Bottoming resistance: increased bottoming resistance with tune-able cross-over rings.
• Reduced body roll: tuned spring setup delivers increased control when turning and cornering.
• Race-inspired durability: premium quality / high tensile / light weight / springs that won’t sag.

Step 12 — Final Checks & Adjustments

• Once the vehicle is lowered to the ground, check all parts which have rubber or urethane components to ensure proper torque. Torque lug nuts to the wheel manufacturer specs. Move vehicle backwards and forwards a short distance to allow suspension components to adjust.
• Turn the front wheels completely left then right and verify adequate tire, wheel, brake line clearance. Test and inspect steering, brake and suspension components for tightness and proper operation.
• RECHECK ALL HARDWARE FOR PROPER TORQUE VALUES AFTER 500 MILES, AND THEN PERIODICALLY AT EACH SERVICE INTERVAL THERAFTER.

Step 13 — Vehicle Handling Warning

• Increasing the height of your vehicle raises the center of gravity and can affect stability and control. Use caution on turns and when making steering corrections.
• Vehicles with larger tires and wheels will handle differently than stock vehicles. Take time to familiarize yourself with the handling of your vehicle.

Step 14 — Wheel Alignment, Headlight, and Safety/Security Systems Adjustment

• It is necessary to have a proper and professional wheel alignment performed by a certified alignment technician. Align the vehicle to factory specifications. It is recommended that your vehicle alignment be checked after any off-road driving.
• In addition to your vehicle alignment, for your safety and others, it is necessary to check and adjust your vehicle headlamps for proper aim and alignment.
• If the vehicle is equipped with active or passive safety/collision monitoring and/or avoidance systems including, but not limited to, camera- or radar-based systems, check and adjust your vehicle’s systems for proper aim and function.

By installing this product, you acknowledge that the suspension of this vehicle has been modified. As a result, this vehicle may handle differently than that of factory-equipped vehicles. As with any vehicle, extreme care must be used to prevent loss of control or roll-over during sharp turns or abrupt maneuvers. Always wear seat belts, and drive safely, recognizing that reduced speeds and specialized driving techniques may be required. Failure to drive this vehicle safely may result in serious injury or death. Do not drive this vehicle unless you are familiar with its unique handling characteristics and are confident of your ability to maintain control under all driving conditions. Some modifications (and combinations of modifications) are not recommended and may not be permitted in your state. Consult your owner’s manual, the instructions accompanying this product, and state laws before undertaking these modifications. You are responsible for the legality and safety of the vehicle you modify using these components.

This document was generated on 2022-07-19 11:58:06 AM (MST).

Website: wpdynamics.wheelpros.com/

References

• WP DYNAMICS - WP Dynamics
• High Performance UTV & Snowmobile Suspensions & Parts | Zbroz Racing

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