The installation of Koni shocks involves specific procedures for both component preparation and physical installation. This article details the steps outlined in available documentation, focusing on front shock preparation and assembly. Information regarding rear shock installation and adjustment is also included.
Front Shock Disassembly and Preparation
The process of preparing Koni front shocks for installation requires several steps, beginning with the removal of existing components. Initial steps involve removing the springs and spring perch from the stock shocks. Following this, attention turns to modifying the Koni shocks themselves.
A centre punch or small tap is used to mark the centre of the bottom of the Koni shock. A 1/8” drill bit is then employed to drill into the marked point. The documentation notes that the presence of shock oil indicates the drilling process is nearing completion. It is recommended to rotate the shock to confirm complete penetration.
Once fully drilled, the shock is inverted, and the oil is drained into a container. The documentation specifically advises against discarding the oil, suggesting it may be useful later. The shock is then pumped several times to ensure complete oil removal.
According to Koni instructions, a line should be marked 50mm from the top of the shock. A pipe cutter, capable of cutting at least a 2” pipe, is then used to cut along this marked line. The documentation suggests a pipe cutter purchased from The Home Depot for $25 can be used. The operation of the pipe cutter involves tightening it around the shock with minimal resistance, rotating it one full turn, tightening further, and repeating until the shock housing separates.
After cutting, the piston is removed from inside the shock housing.
Front Shock Reassembly
Following disassembly and preparation, the Koni shock is reassembled. A rubber sleeve is slid over the shock housing and positioned as far down as possible. The Koni shock insert is then inserted into the housing, which may require some force. The documentation suggests tapping the shock housing against a workbench to achieve a tight and snug fit.
The rubber sleeve is then pulled over the lip of the shock housing to prevent dirt ingress. While the documentation notes the fit is already tight, the sleeve is included and recommended for use.
Finally, the bottom bolt is screwed into place using an 8mm Allen key and torqued to 55 ft*lbs.
Rear Shock Installation and Adjustment
The documentation provides limited information regarding rear shock installation. It states that rear shocks should be installed top first, followed by the bottom.
Prior to installation, it is recommended to invert the shock and fully compress it three to five times to bleed any trapped air. Koni rear Sport dampers are described as fully adjustable, with easy access to adjustment features on all Fox body styles. Users are advised to adjust the dampers according to expected driving conditions.
Additional Considerations
The documentation highlights the importance of retaining the shock oil drained during the disassembly process, suggesting it may have future utility. The use of a specific pipe cutter from The Home Depot is mentioned, providing a potential resource for users undertaking this installation. The torque specification for the bottom bolt (55 ft*lbs) is also provided, emphasizing the need for accurate tightening.
The provided source material is insufficient to produce a 2000-word article. Below is a factual summary based on available data.
Conclusion
The installation of Koni shocks, particularly the front shocks, requires a detailed process of disassembly, modification, and reassembly. This includes drilling and draining the shock, cutting the housing with a pipe cutter, and careful reassembly with a rubber sleeve and appropriately torqued bolt. Rear shock installation is comparatively simpler, involving top-first installation and pre-compression to remove air. Adjustment of rear shocks is possible based on driving conditions.