Attention! Special jaws 67.7824.9513-001 are used to fix the shock absorber and its parts in a vice.
2. After pulling out the shock absorber rod until it stops, unscrew the nut 29 (pic. Front and rear shock absorbers) tank with the key A.57034 / R, remove the working cylinder 21 with the rod 20 and its parts from the tank. Release the reservoir from the vise and drain the liquid from it. Using the key 67.7824.9513–005, remove the guide sleeve 23 of the rod from the working cylinder. Remove the rod assembly with the piston and other parts from the cylinder and drain the liquid. Carefully, using a special mandrel, knock out the compression valve housing 2 complete with parts from the cylinder.
3. Insert the piston rod into the jaws, clamp it in a vise and unscrew the nut 8 of the recoil valve. Remove piston 10 with valves (bypass and recoil), guide sleeve 23, stuffing box 26, clip 25 and other details.
Attention! For the front suspension shock absorber, for the convenience of inspecting the rod surface covered with a casing, it is recommended to press the casing.
4. Disassemble the compression valve, for which remove the clip 6, and then sequentially remove the spring 5, the plate 7 and the valve discs 3 and 4 from the housing 2.
5. Assemble the shock absorber in the reverse order of disassembly, taking into account the following:
- after assembling the compression valve, make sure that the plate 7 and the valve disks have free play;
- press clip 6 onto body 2 with a special mandrel;
- press the compression valve into the cylinder using mandrel 67.7824.9513–004;
- to facilitate the assembly of parts located on the stem, use the guide 67.7824.9513-003;
- the throttle disc 15 of the front shock absorber has three grooves along the outer diameter, and the throttle disc of the rear shock absorber has six;
- the spring of the recoil valve of the front shock absorber is copper-plated, the rear shock absorber is uncoated;
- tighten the recoil valve nut to a torque of 9.8–14.7 N·m (1–1.5 kgf·m);
- tighten the tank nut with the stem fully extended with the wrench 67.7824.9513.002 (tightening torque 68.6–88.2 Nm (7–9 kgf·m).