Penske Racing Shocks 8900 Series - Manual (Page 15)

15
Disassembly / Assembly Instructions
Disassembly Instructions
1. Back the rebound adjuster to full soft and depressurize the remote reservoir.
2. Clamp the body cap eyelet in a vise* with the shaft pointing up. *Soft jaw vise is recommended
3. Unscrew the shaft bearing assembly and remove the shaft assembly.
4. Drain the oil. (Please dispose of properly)
5. Push the reservoir end cap up into the reservoir body. (For the 8100 Series, you must hold the hose)
6. Using a scribe, pry the wire retaining ring out of the reservoir body and remove the reservoir end cap.
7. Looking into the reservoir, you will see a threaded hole in the reservoir floating piston. Using an 8-32 (8100) or
3-8 x 24 (8760) threaded rod, remove the floating piston by holding onto the reservoir body and pulling on the
threaded rod. Drain the oil from the reservoir
8. Use solvent to clean all parts, then dry and inspect them. NOTE: Brake cleaner use is discouraged due to the
possible damaging effects on seals and wipers.
9. Inspect and replace the o-rings as needed.
10. If needed, revalving is done at this point. Clamp the adjustable platform in the vise with the piston pointing up. Remove
the 1/2" ring nut from the top of the shaft assembly to access valving or to change the seals in the shaft bearing.
Assembly Instructions
1. Reassemble the shaft and piston assembly. Before installing the ring nut, there should be no more than .150" shaft to
bottom threads exposed to avoid damaging the nut or shaft threads. Be sure to add sufficient constants to be able to
properly torque the ring nut to 25 ft•lbs (300 in•lbs). [Use constants on CD side for linear pistons. Digressive and VDP
can be varied.]
2. If the jet was removed, add a tiny drop of blue Loctite
™ to its threads and torque to 120 in•lbs (maximum).
3. Torque the jam nut on shaft to 40 ft•lbs (480 in•lbs).
4. With the shock returned to the vise, fill the remote reservoir half full with oil.
5. Hold the remote reservoir above the shock body and look into shock body. When the oil level is above the fitting port,
fill the reservoir to the top with oil. [ 8100 set CD on full hard, #6; 8660 set CD on full soft, turn knob counter clockwise
until it stops against CD body; 8760 high speed CD adjuster (black hex) set on full soft, turn counter clockwise until it
stops against CD body, low speed CD adjuster (silver knob) set on full hard, turn knob clockwise until it stops against
high speed hex.]
6. Before the oil lowers, insert the floating piston and 8100 piston band or 8700/8760 quad ring* into the reservoir body.
*Make sure the quad ring is not twisted.
7. Hold the remote reservoir below the level of the shock with the hose pointing up allowing any trapped air to flow up
into the shock body. Using the handle of a mallet, push the floating piston up into the reservoir body until bottomed.
[8100 CD set on full soft, #1; 8660 CD set on full soft, turn the knob counter-clockwise until it stops; 8760 high speed
CD adjuster (black hex) set on full soft, turn counter-clockwise until it stops, low speed adjuster (silver knob) set on full
soft, turn the knob counter-clockwise until it stops.]
8. Slowly pull the reservoir floating piston back, then push in 2 to 3 inches.
9. Repeat step #7 & #8 until there are no air bubbles seen coming from the reservoir. (When no air bubbles are seen go
directly from step #7 to step #10).
10. Replace the reservoir end cap and snap ring.
11. Pressurize the remote reservoir to reposition the floating piston (approx. 150 psi).
12. Fill the shock body with oil to the bottom of the threads (1/2" from the top of the body).
13. Insert the piston/shaft assembly with the teflon piston band into the shock body, pushing the piston just below the
surface of the oil, until the 2 shaft bleed hole ports are covered.
14. It is very important to remove as much air as possible from the piston assembly. To do this, start by moving the shaft
up slowly and pushing down a few times using a 1" - 2 " stroke, being sure to keep the two ports in the shaft below the
surface of the oil, or air will be sucked back into the piston assembly. Lightly tap the eyelet a few times with a mallet to
assure that all the air is released from the piston. NOTE: this step is very important; take your time, repeat as needed.
15. Slowly pull up on the shaft assembly until the two ports are just below the surface of the oil. Top off with oil to fill the
shock body.
16. Slide the shaft bearing down without moving the shaft until the o-ring contacts the body. Depressurize the remote
reservoir, tighten the shaft bearing. Do not overtighten the shaft bearing.
17. Pressurize the shock to approximately 150 psi. Please call if you have any questions on specific pressures.
NOTES
1) IMPORTANT: Reservoir floating piston must be repositioned before the shaft is inserted into the shock body (refer to
step #11).
2) Penske Suspension Fluid (Silkolene Pro RSF 5 wt.) is recommended. Use of alternate fluids may have an adverse
effect the damper's internal sealing components. (i.e., o-rings)