Mittler Bros Machine & Tool G3 - Manual

N= 8551-290 Gas Port Plug
N
X= 8551-240 Seperator cap O-ring
W= 8551-250 1/4" Washer (2)
V= 8551-260 1/4-28 Nylock Nut
U= 8551-280 Seperator Piston O-Ring
T= 8551-270 Internal Bumper O-Ring
S= 8551-220 Control Piston Band
R= 8551-230 Shaft Guide O-Ring
Q= 8551-160 Bushing Retainer Screw
P= 8551-140 U-Cup (2)
O= 8551-150 Bronze Bushing
M= 8551-090 Seperator Piston
L= 8551-170 Bleed Screw
K= 8551-080 Control Piston
J= 8551-200 #10 Set Screw
I= 8551-120 Spherical Bearing
H= 8551-070 Shaft
G= 8551-050 Cone Spacer
F= 8551-040 Spring Cone
E= 8551-020 Seperator Cap (Bare)
D= 8551-060 Adjustment Nut
C= 8551-030 Shaft Guide (BARE)
B= 8551-010 Shock Body
A= 8551-110 Rod End
the inner surfaces of the shock.
onto the shaft.
bushing out from the bottom side of the shaft guide.
X
24. Depress and extend the shaft several times and you will hear the air bubbles go away. Your shock is now ready to race.
23. Reinstall the bleed screw.
22. Tighten the shaft guide assembly with the shock wrench.
21. With the shaft fully extended out of the shaft guide, reinstall the shaft and shaft guide assembly making sure the shaft stays fully extended.
20. Place the drip cup onto the shock (part # 75566).
19. Fill the shock with oil to the bottom of the internal threads.
18. Allow the loctite to dry for a minimum of 15 minutes, then turn the shock back over in the vice and grip with the shock jaws.
17. Put new loctite on the threads of the shock body and reinstall the separator cap assembly making sure not to get any loctite on
16. Clean all of the old loctite off of the threads of the shock body.
15. Change the o-ring on the separator piston and reassemble separator piston into the separator cap pushing it down enough to
install the new o-ring (x).
14. Push down the seperator piston and remove the internal o-ring (X) then remove the seperator piston.
Do not remove the black closed cell bladder under the seperator piston.
13. Using the slot in the shock wrench, remove the separator cap assembly (this part is loctited on so it may be difficult to remove).
12. Grip the shock body in the vice with the separator cap assembly facing upwards using shock body jaws (Part # 75572).
11. Dispose of all remaining shock oil left in the shock body and clean the body internally to remove any contaminants.
10. Change the o-ring on the outside of the shaft guide and reassemble shaft guide , piston, washers and nut back
9. Clean and reinstall existing bronze bushing (this very rarely wears out) and bushing retainer screw .
8. Insert new u-cup seals facing the proper direction (see drawing above).
7. Remove the old u-cup seals and clean out the shaft guide using cleaner such as brake cleaner or solvent.
6. Remove the bushing retainer screw, and using the end of the shaft (or something similar) push the bronze
5. Remove the 1/4-28 nut from the shaft and pull off the piston, washers and shaft guide assembly.
4. Remove the shock body from the vice and clamp the shaft assembly in the vice.
3. Remove the shaft guide, rod and piston assembly from the shock body using the shock wrench (Part # 75575).
2. Remove the bleeder screw from the shaft guide.
1. Clamp shock into vice using shock jaws (Part # 75570) with the rod end facing upward.
SHOCK REBUILDING
W
W
G-3 SHOCK ASSEMBLY
INDEX
V
U
T
S
R
Q
P
O
M
L
K
J
I
H
G
F
E
D
C
B
A