Front Shock

REMOVAL
1. Remove the front wheels.





2. Remove the brake hose mounting bolts from the damper.
3. Remove the flange bolt.
4. Remove the flange bolt and self-locking nut, then remove the damper fork.





5. Remove the damper by removing the three flange nuts.





DISASSEMBLY
1. Compress the damper spring with the spring compressor according to the manufacturer's instructions, then remove the self-locking nut.

CAUTION: Do not compress the spring more than necessary to remove the nut.

2. Remove the spring compressor, then disassemble the damper.

INSPECTION
1. Reassemble all parts, except the spring.





2. Push on the damper as shown.
3. Check for smooth operation through a full stroke, both compression and extension. The damper should move smoothly. If it does not (no compression or no extension), the gas is leaking, and the damper should be replaced.
4. Check for oil leaks, abnormal noises or binding during these tests.

REASSEMBLY





1. Install the damper unit on a spring compressor.
2. Assemble the damper in reverse order of removal except the damper mounting washer and self locking nut.

NOTE: Align the bottom of damper spring and spring lower seat as shown.





3. Position the damper mounting base on the damper unit as shown.
4. Compress the damper spring.
5. Install the damper mounting rubber, damper mounting washer and a new 10 mm self-locking nut.





6. Hold the damper shaft, and tighten the 10 mm self locking nut.





INSTALLATION
1. Loosely install the damper on the frame with the aligning tab facing inside, then loosely install the two flange nuts.





2. Install the damper fork over the driveshaft and onto the lower arm. Install the front damper in the damper fork so the aligning tab is aligned with the slot in the damper fork.
3. Loosely install the flange bolt into the damper fork.
4. Loosely install a new self-locking nut with the flange bolt.
5. Raise the knuckle with a floor jack until the vehicle just lifts off the safety stand.

WARNING: The floor jack must be securely positioned or personal injury may result.

6. Tighten the flange bolt.
7. Tighten the self-locking nut.
8. Tighten the flange nuts on the top of the damper to the specified torque.
9. Install the brake hose mounts with the brake hose mounting bolts.
10. Install the front wheel.