81 SUZUKI KATANA GSX SZ 1100
RESTORATION
STAGE 4
REASSEMBLY REAR DAMPERS
The assembly of the KONI 7610 rear dampers is straight forward. The O rings are oiled to prevent damage as they are installed on the piston rod seal, O-ring for body & O-ring for piston rod were replaced with the items from Proven Products kit.
Clamp the bottom mount of the damper in the vice then using a 4mm pin spanner or your home made tool, remove the top nut that has the rod seal in it with the pin spanner.
Place a rag around the damper to catch any oil as the rod & piston are removed. The piston can then be removed with a 12mm socket, while holding the damper rod in the vice securing the top eye.
Be aware of the positions of the shims and perforated washers in the piston. If they go back in the wrong order, you might end up with an oil-filled rigid strut instead of a damper.
Seal
Once the piston is removed the ring nut and seal can be removed. The seal can be pushed out using a socket the right size to fit through the hole in the top nut.
The new seal can be inserted using a larger socket. I just place the socket and parts in the vice and squeeze it into the top nut.
To reinsert the nut with the new seal on it, a plastic rod the same diameter as the damper rod inserted into the seal from the inside a steel rod or socket of the appropriate size can be used. This will spread the lip of the seal enough to insert it back on the rod without damaging the seal a little oil will help as well. 80 ml of 5w oil is put into the cartridge.
Damper piston and rod
Then install the damper piston and rod. Screw the top nut down tight onto the new o-ring that comes with the kit. The next thing to do is to clamp the bottom eye into the vice screw on the lock nut & top eye then tighten.
The spring & spring retainer can now installed, remove the rope or spring compressors and your'e done.
The damper will have to be pumped a couple of times to get the oil through it I left that till the dampers where back on the bike.