Front Shock

REMOVAL
1. Remove the front wheel.





2. Remove the brake hose mounting bolt from the damper.
3. Separate the damper and lower arm by removing the damper mounting bolt.





4. Remove the caps from the top of the cowl, then remove the self-locking nuts.
5. Remove the damper assembly.

DISASSEMBLE





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 as shown.

INSPECTION
1. Reassemble all parts, except the spring.





2. Push on the damper assembly and check for smooth operation through a full stroke, both compression and extension.

CAUTION: The damper should move smoothly. If it does not (no compression or no extension), the gas is leaking, and the damper should be replaced.

3. Check for oil leaks, abnormal noises or binding during these tests.

ASSEMBLE
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.





3. Position the damper mounting base on the damper unit as shown.

NOTE: Follow the manufacturer's instructions

4. Compress the damper spring.

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

5. Install the damper mount washer and a new self-locking nut.





6. Hold the damper shaft, then tighten the self-locking nut.

INSTALLATION





1. Reposition the damper on the frame with the welded nut of the hose bracket facing outside.
2. Install the damper end on the lower arm, then loosely tighten the mounting nut.

NOTE: The bolts and nuts should be tightened with the vehicle's weight on the damper.

3. Secure the damper mounting bolt using a new self-locking nut.





4. Secure the damper assembly to the frame with the new three self-locking nuts.
5. Install the caps in the top of the cowl.
6. Install the brake hose mounting bolt.