Section 08
SUSPENSION
Subsection 02
(FRONT SUSPENSION)
08-02-4
VMR2004_026_08_02A.FM
NOTE:
If an oil mist occurs, it is an indication of a
faulty sealing of the floating piston either caused
by wear of shock absorber or floating piston seal-
ing.
Remove tool from shock.
Remove valve from shock absorber.
Using an appropriate open wrench, unscrew
shock absorber seal carrier cover.
Gently pull piston rod out. Remove slowly to re-
duce oil spillage and prevent piston seal damage
on body threads. Wrap body in a rag to capture oil
overflow while removing piston rod.
Empty oil from shock absorber. Ensure to dispose
oil according to your local environmental regula-
tions.
Remove floating piston as follows.
Hold a rag over shock absorber end to catch float-
ing piston. Allow room for parts to leave shock ab-
sorber. Using compressed air pressure in valve
hole, carefully push piston out.
Clean inner walls of shock absorber and reservoir
with pulley flange cleaner (P/N 413 711 809). Be
careful not to splash O-rings, piston and seals etc.
Dry parts with compressed air.
Inspection
Check the following:
– Compression bumpers for chipping, cracking
or missing.
– O-rings for nicks, cuts or cracks.
– Piston rod for straightness, wear, nicks or
burrs.
– Seal carrier and rod seals.
– Piston seal ring for wear.
– Valve discs for kinks or waves.
– Inner walls of shock absorber and reservoir
for scratches, burrs or excessive wear.
– Floating piston seal for wear, cuts, chipped or
nicked edges.
– Inner wall of shock absorber for excessive
wear in working area of floating piston.
Replace any defective/worn part.
Valving
Rebound stack:
Ø32 x t0.30
Ø28 x t0.30
Ø25 x t0.15
Ø18 x t0.10
V02J1DA
V02J1EA
V02J1FA
Summary of Contents for DS 650
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Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
