ANUAL SERVICE M

PISTON RING REPLACEMENT

Apply fork oil to new O-rings and piston ring.

Place the piston ring guide attachment over the pis­ton and install new O-rings and piston ring into place by hand.

TOOL:

Piston ring guide

070MG-KZ30100 not available in U. S.A.

Compress the piston ring against the ring groove and seat the piston ring into the ring groove.

DAMPER ROD DISASSEMBLY

To keep lint or dirt from getting onto the damper rod parts, do not wear gloves while working on the damper rod.

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

Unstake the damper rod end nut with a file as shown.

Be careful to file the end nut by hand so that the O. D. of the rod end is about 10 mm (0.4 in). Be care­ful not to over-file.

Turn the end nut back-and-forth in 1/4 turn incre­ments until it loosens, then rotate another 1/4 turn and repeat turning back-and-forth until the nut loos­ens completely.

If the damper rod is cracked or damaged when removing the end nut, replace the damper rod assembly with a new one.

Remove the burrs from the damper rod end with a

file and chase the threads with a die.

DIE: 12 x 1.25 mm

Clean the damper rod with solvent after chasing the

threads.

• Use a piece of mechanics wire to keep the removed valves in the correct order.

• Keep dust and abrasive away from all damper rod parts.

• Thoroughly clean the valves in solvent and blow them dry with compressed air if they have been disassembled and separated.

• Be careful not to get solvent on the O-ring and piston ring.

• The valve arrangement and number of valves shown is typical and may not represent this model exactly.

Remove the valve stopper, rebound valves and pis­ton from the damper rod.

Remove the compression valves and valve stopper.

Chase the threads with a die and clean with oil. Back out the damping adjuster.

Wrap the threads of the damper rod with tape.

Remove the rod guide case from the damper rod.

Remove the end plate, rubber stopper and rubber seat from the damper rod.