A-pillar bulkhead on production models since 1983
1. As in the case of the front struts on early models, the removal and installation of the strut should be done by a specialist with the necessary tools.
2. If you have enough experience and have a shock absorber spring compressor, you can replace the spring yourself. You will need a set of new fasteners.
3. The final tightening of the damper rod nut is done after the strut is installed on the machine.
Removal and installation of the lower arm of a forward suspension bracket (release models since 1983)
1. Install cables to hold the spring compressed.
2. Loosen wheel nuts or bolts on desired wheel. Raise and support the front of the machine and remove the front wheel.
3. Remove the bolt securing the anti-roll bar link to the lower suspension arm.
4. Loosen the lower control arm ball joint nut. Using a special ball joint remover, disengage the joint, remove the nut and pull the ball joint pin out of the stub axle.
5. Remove the lower control arm pivot bolt (front) and 2 silent block mounting bolts (behind). Remove the lower control arm from the machine.
6. If it is necessary to replace the lever bushings, clamp it in a vise and remove the pivot nut with washer. After that, you can remove the silent block bracket from the lever.
7. Replacement of bushings must be carried out by a specialist with special equipment. In principle, it requires a vise, a set of tubes of suitable diameter and liquid soap.
8. Before installing the lever in place, align the silent block bracket on it as follows.
9. Install the bracket on the lever and fix it with a nut and washer, without tightening the nuts yet.
10. Place the lever with bracket on a flat surface. Temporarily insert a bolt or bar with a diameter of 12 mm into the front bush, placing a bar 23 mm thick under it. Clamp the bracket with a clamp so that it is located on the surface without distortions (see b/fig. 12.102).
11. While holding the lever, tighten the pivot nut to the correct torque. Remove the clamp from the bracket and check that its edge is still in contact with the surface.
12. Install the lower arm on the machine. Insert the support pin into the stub axle. Insert pivot bolt and silent block bolts. Note that the support pin must not be lubricated or wiped with solvent.
13. Tighten the pivot bolt and the silent block bolts to the correct torque.
14. Tighten the ball joint nut to the correct torque.
15. Connect the anti-roll bar link to the lever and tighten its bolt to the desired torque.
16. Replace the wheel, lower the machine and tighten the wheel nuts or bolts.
17. Remove the cables holding the spring in a compressed state.