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1. Unscrew both set-crew (2mm allen key).
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2. Unscrew complete anti-bottoming assembly from main shock shaft assembly (20mm open end wrench)
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3. Inspect anti-bottoming piston outer diameter for damage. Light scuffs or scratches are normal and won't affect performance. Notice that piston assembly is loosely fit on the piston holder, significant axial and radial play are normal.
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4. Unscrew the lock nut (13 mm) and remove the piston assembly. This nut shall be discarded and not reused for reassembly.
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5. Gently clamp the outer diameter of piston assembly in a soft jaw vise. Apply heat on piston with a propane torch to soften the thread locker compound. Unscrew the shim holder (15mm). Caution: Ensure to not damage the shim holder end face during disassembly.
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6. Inspect each shim for presence of cracks or damage.
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1. Use a wire brush to clean piston and shim holder thread to remove thread locker compound
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2. Build the shim stack and insert it on the shim holder. Caution: Shim stack shall be 1mm thick maximum.
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3. Apply high strength (red) thread locker on shim hold thread and screw it in piston at 13 Nm. • Caution: Ensure no thread locker compound ends up on the shims. This will severely affect performance. • Caution: Piston is not identical on each face. Shim stack shall be installed against the taper face without chamfer on holes.
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4. !!!Important!!! Inspect end face of shim holder. This face shall be perfectly flat without any protrusion to achieve good sealing during operation. If damage occurred, use a file to remove burrs.
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5. Install piston assembly on piston holder. Use a new locking nut and torque it to 13 Nm.
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6. !!!Important!!! Ensure the distance between shaft tip and contact surface on washer is between 12 and 15mm. To adjust this distance, add or remove washer and/or modify the shim stack.
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7. Install the anti-bottoming assembly on the shock main shaft assembly. Torque is 41 Nm.
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8. Apply low strength thread locker (blue) on set scew. Torque them to 3 Nm.
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