Disassembly and Reassembly

DISASSEMBLY






HINT: PreRunner is the model described below.
RZN191L-TRPDKAB, RZNI96L-CRPDKAB, VZN195L-CRPDKAB

REMOVE SUSPENSION SUPPORT AND COIL SPRING





a. Using SST, compress the coil spring until there is a clearance on both ends.
SST 09727-30021

NOTICE:
^ To avoid damage to SST, set SST arms to allow clearance to hold a 8-roll coil between them.
^ Do not compress the coil spring more than necessary.
^ Do not use an impact wrench. It will damage the SST.

b. Remove suspension support center nut.
c. Remove the 3 retainers, 2 cushions, suspension support and coil spring.

INSPECTION
INSPECT SHOCK ABSORBER





Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one.

NOTICE: When discarding the shock absorber, see DISPOSAL.

DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD





2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside.

CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling.

REPLACEMENT





1. REMOVE BUSHING
Using SST and a press, remove the bushing.
SST 09506-35010, 09632-36010





2. INSTALL NEW BUSHING
Using SST and a press, install a new bushing.
SST 09506-35010, 09632-36010

HINT: Do not apply grease or oil to the bushing.

REASSEMBLY





1. INSTALL COIL SPRING TO SHOCK ABSORBER
a. Using SST, compress the coil spring.
SST 09727-30021

NOTICE:
^ To avoid damage to SST, set SST arms to allow clearance to hold a 8-roll coil between them.
^ Do not compress the coil spring more than necessary.
^ Do not use an impact wrench. It will damage the SST.

b. Install the coil spring to the shock absorber.

HINT: Fit the lower end of the coil spring into the gap of the spring seat of the shock absorber.





2. INSTALL SUSPENSION SUPPORT
a. Install the 2 cushions, 3 retainers and suspension support to the rod.
b. Temporarily tighten a new suspension support center nut.
c. Position the suspension support so that a line drawn between the 2 bolts would be parallel to the direction of the lower bushing.
d. Remove the SST.
SST 09727-30021

HINT: After removing the SST, again check the direction of the suspension support.

e. Torque the suspension center nut.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)