Note: Steps 4-8 apply to MARS Elite and MARS Super only.
4. Remove the clear plastic detent sleeve and capture the 1/8 dia. detent ball.
5. Adjuster needle may be unscrewed from the shaft.
6. Remove the retaining ring then slide off the cup washer, & bottom out bumper. Do not remove
the threaded plastic end cap at this time. Sliding the seal over the retaining ring groove may
damage the seal.
7. Clamp shaft in soft jaws or collet and remove piston as a complete unit, slide end cap off of
top of shaft.
8. Remove the valve nut and disassemble damping stack, make note of the exact order of the
shims and spacers.
REBOUND DAMPER INSPECTION
1. Check the shaft for scratches, wear, or other obvious damage.
2. Check the seal gland and end cap seal grooves for damage.
3. Check shims for permanent bends or damage.
4. Check all other parts for obvious damage, replace if necessary.
5. Replace all seals that have been removed.
6. Clean shims using lint free rags or paper towels.
MARS REBOUND DAMPER ASSEMBLY
1. Install all o-rings and seals that you removed.
2. Grease all seals lightly with seal grease.
3. Insert into right leg and thread in end cap. Torque 30 in-lb. (3.5N-m) max.
4. Install outer leg assembly, see Figure 9. Add 5 WT Maxima or equivalent oil. Do not over fill.
Check oil level, see Figure 8.
MARS ELITE AND MARS SUPER REBOUND DAMPER ASSEMBLY:
1. Install all o-rings and seals that you removed.
2. Grease all seals lightly with seal grease.
3. Assemble shim stack and spacers onto the piston seat in exact order that they were removed.
Apply a small amount of blue Loc-tite to piston seat threads install and hand tighten nut. Be
sure large blow off washer will slide over piston spacer and compress the small spring. Torque
12 in-lb. (1.3 N-m) max, over tightening will damage the piston.
4. Apply a small amount of blue Loc-tite to piston seat threads. Install piston seat into shaft. Use
wrench flats on piston seat to torque piston seat to 30 in-lb. (3.5 N-m) max.
5. Install lower needle gently into shaft; thread until it stops then back off two turns for initial
adjustment.
6. Slide shaft assembly through the plastic end cap, slide on 2nd STG Elastomer, cup washer and
snap ring, place detent ball in place and slide clear detent sleeve over it.
7. Insert into right leg and thread in end cap. Torque 30 in-lb. (3.5N-m) max.
8. Install outer leg assembly ,see Figure 9.Add 5 WT Maxima or equivalent oil. Do not over fill.
Check oil level, see Figure 8.
