RACE TECH HI-PERFORMANCE 

SPORT SERIES FRONT SPRING KIT 

<QFSK_Sport_01.doc> QFSK ATV Sport Series Spring Kits    M Wiley-Race Tech ã 6-09-08  

INCLUDES: qty 2 of each: Main Springs, Secondary Springs, NPL Collar, Go-Between Collars, and Sizing Rings.

TOOLS REQUIRED: Service Manual, Vise with Soft Jaws TMVJ 065 or equivalent, TSPA 01 Preload Adjusting Tool or Spanner Wrench, ¼” Flat Blade Screwdriver, File (some applications), TSSM 01 Sag Master or Calipers.

DIGITAL VALVING SEARCH (DVS) printout: See DVS at www.racetech.com for your custom spring setup specs.

 

Support the front of the ATV securely; remove front shocks per the procedure in your service manual.  Install the Race Tech Spring Kit as follows:

Note: Click on the images to enlarge.

Stock Spring Disassembly

D1 Clamp Shock into a vise with Soft Jaws

D2 Loosen Lock Ring.

D3 Remove all spring preload using a Spanner Tool or by loosening the Collar by hand.

D4 Clean and lube the threads.

Remove the Retaining Collar
 
D5 Use a small Screw Driver or similar tool.  Find the opening in the plastic Dust Shield and gently pry the Bottom-out Bumper away from the end of the Shock approximately 50mm (2”).

D6 Compress the Spring slightly by hand and remove the Retaining Collar being careful not to pinch your fingers!

D7 Remove the stock Spring and Dust Shield.

Modify the Stock Eyelet (Yamaha Models)
Skip this step if your Go-Between Collar fits over the Eyelet 
 
M1 Try installing the Go-Between Collar over the Shock Eyelet. If it does not fit you will need to modify the Eyelet slightly.

M2  It only takes a few minutes to chamfer the edges of the Shock Eyelet with a file. Remove approximately .5mm (.100”) from each edge as needed so the Go Between Collar slips on.
 

NPL Collar and Spring Assembly
 
A1 Install the NPL Collar (single flange) with the long end of the flange facing towards the bottom of the Shock.
 
A2 Install the short Secondary Spring over the NPL Collar.
 

A3 Install the Go-Between Collar (has two flanges) with the short flange towards the NPL Collar.
 
A4 Install the Main Spring over the Go-Between Collar.
 
A5 Do not use the stock plastic dust shield.
 

A6 Install a Sizing Ring supplied in the Kit.
 
A7 Carefully pull down the Bottom-out Bumper and Main Spring, slide up the metal cup and insert the Retaining Collar under the metal cup. 
 

Preload Setup
 
P1 Refer to the DVS Specs from racetech.com. 
 
P2 Adjust the Preload Collar to set the initial preload with Tape Measure.
 
 
Note: 
 
Preload is the amount spring set is compressed initially. Measure the overall length of the spring set with no tension for first measurement. Use the preload collars to compress the spring set the amount specified in the DVS specs.   
 

Tighten the Lock Ring
 
A10 Gently tighten the Lock Ring against the Preload Collar being careful not to change the Gap.
 
A11 Repeat the procedure for the second shock.