ANUAL SERVICE M

BLADDER REPLACEMENT

• Set the rebound adjuster and compression adjuster counterclockwise to the softest position.

• Replace the bladder when oil leaks around the chamber cap or oil spills out when releasing the nitrogen from the reservoir.

• Perform this procedure before draining the oil from the damper.

Depress the valve core to release the nitrogen from

the reservoir.

AWARNING

The chamber cap will be under significant pressure and could cause serious injury. Release all nitrogen pressure before disas­sembly.

Wear protective clothing and adequate eye protection to prevent injury and debris entering your eyes.

Remove the valve core.

Put a suitable tool on the chamber cap and push it in by lightly tapping on the tool with a plastic ham­mer until you have good access to the stop ring.

NOTICE

To avoid damaging the threads of the gas valve, install the valve cap before depressing the chamber cap.

Two small screwdrivers and a shop towel are required to remove the stopper ring.

The stopper ring groove in the reservoir is ramped toward the inside to give the stopper ring a square shoulder on which to seat securely.

To remove the stopper ring, first push one end of the stopper ring out of its groove, then slip the sec­ond screwdriver between the stopper ring and the reservoir to act as a ramp.

Now, use the other screwdriver to pull the stopper ring completely out.

• Check the stopper ring groove for burrs. Remove any burrs with a fine emery cloth before pulling the damper rod out of the case.

Set the shock absorber in a vise with a piece of wood or soft jaws to avoid damage.

Using a suitable squeeze bottle, fill the reservoir with the recommended shock oil.

RECOMMENDED SHOCK OIL:

Pro Honda HP Fork Oil 5W or equivalent

Slowly pump the damper rod until no air bubbles appear in the valve core hole, then pull the damper rod all the way out.

Install the valve core securely.

Wear protective clothing and a face guard to protect your eyes and face in case the chamber cap pops out quickly and forcibly.

Remove the chamber cap and bladder following the procedure below:

NOTE:

• The chamber cap will be removed with hydraulic pressure so its force can be significant consider­ing the air in the bladder.

1. Wrap the shop towel around the chamber cap. Compress the damper rod slowly, to force the chamber cap out.

2. Set the damper in a vise with soft jaws with the damping adjuster facing up, being careful not to distort the damper body. Remove the damping adjuster and O-rings.

NOTICE

Do not over-tighten the vise. Damage to the clamper case will result.

3. Fill the damper with Pro Honda HP Fork Oil 5W or equivalent through the damping adjuster hole, while slowly pulling the damper rod out.

4. Reinstall the damping adjuster after filling the damper.

• The damper must be kept upright to prevent oil from leaking out.

5. Place the damper with the reservoir chamber cap facing up.

Clean the inside of the reservoir and fill it with rec­ommended shock oil.

RECOMMENDED SHOCK OIL:

Pro Honda HP Fork Oil 5W or equivalent

Apply light coat of shock oil to the lip of the bladder, and press the chamber cap into the reservoir to about 1.0 - 2.0 mm (0.04 - 0.08 in) below the stop­per ring groove.

Install the stopper ring in the groove of the reservoir securely.

Temporarily fill the reservoir with air slowly until the chamber cap seats against the stop ring.

Make sure the chamber cap face is level with the reservoir face.

If the chamber cap does not seat fully, the chamber cap may fly out when filling the reservoir with nitro­gen.

Release the air from the reservoir by depressing the valve core.

Bleed the air from the shock absorber bladder (page

15-26).

Fill the reservoir with nitrogen to the specified pres­sure (page 15-27).

RESERVOIR