(Leave shock pressurized to begin, as it will ease removal of wipercap)

  1. Clean shock, and put into soft jawed vice or something to hold it upside-down.
  2. Loosen wiper cap with a spanner wrench/channel lock pliers. Slide wiper cap assembly up shock shaft.
  3. De-pressurize shock completely.
  4. Push sealhead assembly down to expose snap ring. Remove snap ring.
  5. Remove shaft / sealhead assembly, by rocking back and forth and pulling out at the same time. (watch for wearband on piston to come off as assembly is removed from shock body) Set aside.
  6. Clamp shaft assembly in a vise, using the eyelet. Remove valving and piston. Make sure to keep all valve shims and piston in the same order as removed if you plan to re-install any portion.
  7. Inspect all valve plates and damping piston, look for cracks or any signs of fatigue.
  8. Check shaft to see that it is not bent or has any deep pits. Replace if required.
  9. Replace old valving with new in the same order the old was removed. (largest shims are always against piston) Begin by installing compression valving from smallest to largest on the shaft. Re-install piston with large openings facing upwards. Stack rebound valving against piston from largest to smallest.
  10. Install lock-nut. Torque nut to 30 ft./lb.
  11. Depress reservoir end cap. (Schrader end). Remove snap ring and reservoir end cap.
  12. On remote reservoir, check that the IFP is 8” from the open end of the reservoir. On the piggyback reservoir, the IFP should be 6” from the open end of the reservoir. If piston is less than this distance, push the IFP down to the appropriate level. This will also force any en-trapped air into the shock body.
  13. If needed, fill the body with 5wt. oil, leaving a 2” air gap at the top.
  14. Insert shaft and valving assembly into shock. Gently move the shaft assembly in and out until all the air bubbles are removed. You are trying to bleed any air that may be trapped in the shock.
  15. Check the IFP location, it may have moved. Reset if needed.
  16. Top off the shock with oil to about 1/4” from the top.
  17. Slowly insert the sealhead assembly into the shock body. Oil will typically spill out of shock as sealhead goes in. Push the sealhead in so that the snap ring can be installed.
  18. Install the snap ring. Check to be sure it is completely in its groove. This is very important!
  19. Install wiper cap assembly. Screw it onto the sealhead assembly until it is snug.
  20. Lube and install the reservoir end cap. Install the last snap ring.
  21. Compress the shaft all of the way into the shock. This should set the reservoir end cap into position. (It should make a pop / snap sound).
  22. Pressurize the reservoir with 120-180 psi. Install reservoir valve cap.
  23. Tighten down wipercap cap assembly.
  24. Remove the shock from the vise. Compress the shock to make sure it is working properly.