Section 08
SUSPENSION
Subsection 02
(FRONT SUSPENSION)
08-02-6
VMR2004_026_08_02A.FM
Slowly push piston into shock absorber to prevent
displacement of the floating piston. Apply a short
stroke of slight up and down movement to allow
air to pass through piston stack assembly.
Gently tap with a clean soft hammer on the shock
eye to dislodge air trapped in the submerged piston.
Be careful not to drive the shaft any deeper into the
oil than it is necessary to just cover the shim stack.
Be also careful to maintain oil above piston stack.
Otherwise repeat the operation.
Seal carrier assembly can now be screwed into
body. This should be done slowly to minimize float-
ing piston displacement.
After the seal carrier is completely installed, avoid
pushing the piston rod into the body until the nitro-
gen charge is added.
Using an appropriate open wrench, torque seal
carrier cover to 75 N•m (55 lbf•ft).
Use the gas shock valve tool (P/N 529 035 570)
and tightly install it to the nitrogen tank.
1. High pressure hose
2. Two stage regulator
3. High pressure cylinder filled with industrial grade nitrogen (N
2
)
4. Gas shock valve tool
Proceed as follows:
1. Adjust nitrogen tank regulator to 0 kPa (0 PSI).
2. Install the gas refill needle type shock tool (P/N
503 190 102) on gas shock valve tool
3. Turn tappet valve of gas shock valve tool clock-
wise up to the end.
4. Place the needle guide of gas refill tool on the
shock valve. While depressing the detente pin
of the gas refill tool and pushing forward the
needle assembly, insert the needle through the
rubber core of the pressure valve assembly of
the shock. Ensure to firmly keep the tool sat
squarely on shock valve.
WARNING
Do not use any other type of gas than Nitrogen
(N
2
).
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Summary of Contents for DS 650
Page 1: ......
Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
