RACE TECH HI-PERFORMANCE

ATV REAR RACE  SPRING KIT LTR450

<IP_QRSK02.doc> QFSK ATV Race Series Spring Kit      E. Rios-Race Tech ã 8-12-08

INCLUDES: NPL Collar, NPL Spring and Go-Between.

TOOLS REQUIRED: Service Manual, Vise with Soft Jaws TMVJ 065 or equivalent, TSPA 01 Preload Adjusting Tool or Spanner Wrench, ¼” Flat Blade Screwdriver, Hydraulic Spring Compressor, TSSM 01 Sag Master or Calipers.

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

Support the rear of the ATV securely; remove rear shock per the procedure in your service manual.  Install the Race Tech Spring Kit as follows: (NOTE: your model may look different.)

Note: Click on the images to enlarge.

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.

D5 Use a small Screwdriver 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.

D6 Using a Hydraulic Spring Compressor, compress the stock Spring and remove the Spring Retaining Collar.

D7 Remove the stock Spring.

 

Note: The Suzuki LTR450 rear Shock Absorber has a deep drop style Lower Spring Retaining Collar which requires the Spring to be compressed about 35mm (1.5”) to be removed. A Hydraulic Spring Compressor (shown) should be used to safely remove the stock Spring and install the new Race Tech Base Kit and Main Spring. Many suspension shops will have a Spring Compressor such as this. If you are unable to find a shop in your area please feel free to contact Race Tech for details on purchasing a Spring Compressor. You can also send your Shock to Race Tech and we will be happy to install the Spring Kit for you.

Assembly
NPL Collar 
 
A1 Install the NPL Collar (single flange) with the long end of the flange facing towards the bottom of the Shock.
 
A2 Install the NPL Spring over the NPL Collar. The NPL Spring is the softest of the three springs.
 

A3 Install the Step-Cut Go-Between Collar. The Collar has a step on the inside diameter. The larger diameter must go towards the threaded portion of the shock body for proper clearance. 
 

A4 Install the Main Spring (sold separately).  Refer to Race Tech’s Spring Search on racetech.com for Spring Series and rate selection. 

 
 
 

A5 Install the original Lower Spring Retaining Collar using a Hydraulic Spring Compressor.

             

NPL Gap Setup

A6 Refer to the DVS Specs from racetech.com.

A7 Adjust the Preload Collar to set the Gap between the flanges of the NPL and Go-Between Collars.  Use a Caliper or Tape Measure.

A8 Gently tighten the Lock Ring against the Preload Collar being careful not to change the Gap.

NPL Gap is the distance between the NPL Collar Flange and the Go-Between Collar Flange that extends into the NPL Spring.

This distance determines the ride height of the ATV. A larger Gap equals a lower Ride Height; a smaller Gap creates a higher Ride Height.