Shocks.
The XRay shocks are a typical build. There isn't anything special about building them as compared to other similar shocks. So far this seems to be the only part that doesn't impress me. Everything els on this kit is BEEF except the shocks. The body's seem thin and the caps seem a bit thin as well. I ran into several mis-manufactured parts. I will document them as they come up.
The first step is to install the pistons onto the shaft with the metal washer going on first. Here is the first issue I ran into. The hole in the metal washer wasn't large enough to let the small end of the shaft fit. I used a round jewelers file and enlarged the hole. It took only 30 or so seconds to do this. 3 of the 4 washers were to small. Place the metal washer on the shaft followed up with a piston. Take note of the piston and be sure to install it with the protruding center hub pointed up. followed with the metal nut.
(Do not over tighten the nut) Tighten the nut only until it touches the piston, no more. There is no need to crank down on it.
My kit contained an upgraded piston set. They are white instead of black and are made of a softer plastic to keep them from splitting. Choose the proper piston for your setup. If you look closely you will see that one set has a conical shape to the hole and one set doesn't. Take care in choosing the proper pistons. Make sure that you use a sharp blade and remove any leftover molding plastic.
Here is where I ran into my second issue. The g-clip groove had not been completely machined and there was leftover metal still attached. I cleaned it up the best I could but have requested a replacement.
The next step is to install the shaft seals.
Lube all the parts with shock oil before you install them. Start with a rubber O-ring and slide it into the bottom of the shock. be careful not to get it twisted. Place a plastic washer over the o-ring and use your hex wrench or a dowel to tamp it down. Place another O-ring then plastic washer over the last set. for a total of 2 o-rings and 2 washers. Follow this up by securing it with the G-clip. Place The un-bent end of the clip onto the groove on the inside and chase it around with your finger until it is completely installed. Take your time and look to see that its in the groove all the way around.
Lube the shaft and insert it into the top of the shock body and down through the bottom of the shock. Don't force it through the bottom. Go slow and make sure its well lubed. You want to be careful not to tear the o-rings with the threads on the end of the shaft.
Place the shock end on the shaft. Hold the shaft just above the threads with a wire cuter if your not the proud owner of a shock shaft holder. Screw it on all the way until there are no threads showing.
Fill the shock bodies up about 95% to the top with the proper fluid weight for your setup. Pump the piston one or two times to get the air out from under the piston. Set the shocks aside to let the air bubbled rise to the top.
Next we need to build the cap.
Place the plastic cap into the aluminum cap nut. Be sure to align the groves properly and make sure the cap is fully seated in the nut. Then place the diaphragm into the body of the nut with the bubble facing out. Use a small blunt object to chase the edges of the diaphragm to be seated at the bottom of the cap.
Next place the cap assembly over the filled shock body and slowly screw it on. There should be excess fluid and air bubbles escaping from the small holes on the side of the cap. Hand tighten the cap. Do not over tighten.
You should be able to push the shaft all the way in without restriction. If there is any restriction at all, loosen the cap and push the shock shaft up slowly allowing some fluid to escape. Tighten the cap and check again. When the shaft is pushed in, it should not rebound more then 1/4 inch. If it does follow the previous step to remove a small amount of fluid.
Slide the silicone shock boot over the shock end and seat it in the groove on the outside of the shock body. Slide the top spring retainer over the body making sure the flat part goes to the top. Slide the spring onto the shock and secure it with the bottom retainer. Be sure to capture the end of the silicon boot with the bottom spring retainer.
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