Section 08
SUSPENSION
Subsection 02
(FRONT SUSPENSION)
VMR2004_026_08_02A.FM
08-02-3
Replace shock if any of these conditions are found.
On both ends, check the bushings for excessive
wear or other damages. Replace bushings in pair.
Assembly and Installation
For assembly and installation, reverse the disas-
sembly and removal procedures. Pay attention to
the following details.
Extend the piston before installing spring, spring
seat and snap ring.
On
Baja and Baja X models
, reinstall the shock
protector, make sure not to block venting holes.
On
Baja X models
, reinstall piston rod of shock
absorber to the bottom lower A-arm.
Adjustment
Preload Adjustment
Shorten the spring for a firmer ride and rough road
condition.
Lengthen the spring for a light load and a smooth
road condition.
SHOCK ABSORBER REBUILDING
Baja X Models
Remove spring and adjuster. See SHOCK AB-
SORBER ASS’Y above.
Disassembly
Clean all the parts prior to disassembling.
Tightly secure the shock absorber bottom eyelet
in a vise with soft jaws.
CAUTION:
Never clamp on shock absorber body.
Remove screw on top of valve.
Place the needle guide of gas refill needle type
shock tool (P/N 503 190 102) on the shock valve.
Press the detente pin and push forward the needle
assembly very slowly towards rubber of needle
valve.
Push on shock tool valve center rod to release gas
pressure.
WARNING
Adjust both springs to the same load. Uneven
adjustment can cause poor handling and loss
of stability, and/or control, and increase the
risk of an accident.
WARNING
Whenever working with high pressure gas,
use eye wear protection. Never direct gas
pressure toward anybody. Allow gas to es-
cape before removing components.
V02J1CA
503 190 102
A32F37A
Summary of Contents for DS 650
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Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
