Note. Special jaws 67.7824.9513-001 are used to fix the shock absorber and its parts in a vice.
After pulling out the shock absorber rod until it stops, unscrew the nut 29 (rice. 4-18) the reservoir with the wrench A.57034/R, remove the working cylinder 21 complete with the rod and compression valve 2 from the reservoir. Release the reservoir from the vise and drain the liquid from it.
Using the key 67.7824.9513-005, remove the rod guide 23 from the working cylinder. Remove the rod 20 complete with piston 10 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.
Put the rod assembly with the piston 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), the guide sleeve 23 of the rod, the stuffing box 26 of the stem, the clip 25 of the stuffing box and other details.
Note. For the front suspension shock absorber, for the convenience of inspecting the surface of the rod, covered with a casing, it is recommended to press the casing from the rod.
Disassemble the compression valve, for which remove the clip 6, and then sequentially remove the spring 5, the plate 7 and the valve disks 4 and 3 from the housing 2.
Shock absorber assembly carry out 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 two grooves along the outer diameter, and the throttle disc of the rear shock absorber has three;
- tighten the recoil valve nut to a torque of 11.76-15.68 Nm (1.2-1.6 kgf·m);
- tighten the reservoir nut with a wrench 67.7824.9513-002 to a torque of 68.6-88.2 Nm (7-9 kgf·m).