Overhaul

DISASSEMBLY





1. Using the special tools, (J38402, A-20), spring compressor, compress the coil spring until there is only a little tension on the strut.

NOTE: Do not use an impact gun.





2. Remove the self-locking nut at the top end of shock absorber.
3. Remove the special tool, bracket, spring pad and coil spring.

INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the spring for correct height, deformation, deterioration or damage.





3. Check the shock absorber for abnormal resistance or unusual sounds.

NOTE: When discarding the gas pressurized shock absorber, follow the disposal procedure.

DISPOSAL
1. Fully extend the shock absorber rod.





2. Drill a hole on the A section to remove gas from the cylinder.

CAUTION: The gas coming out is harmless, but be careful of chips that may fly up when drilling.

REASSEMBLY





1. Install the special tools (J38402, A-20), compress the spring. After spring is fully compressed, install it on the shock absorber assembly.





NOTE:
1. Do not use an impact gun.
2. Coil spring installation chart to load classification.

2. After seating the dust cover, upper spring pad, bushing (13), bracket, bushing (A) in this order, tighten the new self-locking nut temporarily.





3. Position the upper and lower ends of the coil spring in the upper spring pad and lower spring seat grooves correctly





4. Place the bracket to align the bracket bolt with the projection of the fork bracket in a straight line.
5. Remove the special tools (J38402, A-20).





6. While holding the piston rod, tighten the new self-locking nut to the specified torque.
Tightening Torque
Piston rod to bracket nut: 20 - 25 Nm (200 - 250 kg-m, 15 - 18 ft. lbs.)