FRONT SUSPENSION Assembles ncluded 3:1 K3601 021AA LOWER WISHBONES In hs goup: - 3:2 K3601 022AB UPPER WISHBONES 3:3 K3601 023AA STABILISER BAR 3:4 K3601 286A U PRIG HTS 3:5 K3601 183AB FRONT STABILISER BAR LINKAGE K3601 021AA LOWER WISHBONE KIT Tools equed fo assembly of hs goup: - 19mm Spanne 2 Toque Wench wh ange 8-50 Nm 1 13mm Socke o f oque wench 1 Vene allpe o Measung Tape (mm) 1 3mm Allen Key 1 *Snapon 60º 17mm Spanne (P# - SVSM17) 1 *Snapon 3/8 Dve Powe / Beake Ba (P# - F12L) 1 *Snapon 3/8 Dve 22mm Socke (P# - Fm22) 1 5mm Allen Key 1 10mm Spanne 1 * The manufacues name and pa numbes ae menoned as a efeence o specals ools equed fo he assembly of he wshbone ball jons o he upgh assembles. Nu M12 Nyloc K3601 183AB FRONT STABILISER BAR LINKAGE K3601 022AB UPPER WISHBONE KIT Washe 12mm fla K3601023AA STABILISER BAR opygh Bkn as (Py) Ld Qy Nu M12 Nyloc Upgh assembly L/H Wshbone shock space Uppe wshbone Washe 10mm fla Nu M10 x 1 pch Bake Ppe mn bk
GROUP THREE 3:1 LOWER WISHBONES - K3601021AA 1s Edon omponens n hs assembly Qy Pa Numbe I Bol M12 x 90 2 B5358057AA Nu M12 Nyloc 4 B5358060AA Washe 12mm Fla S/S 12 B5358061AA v Bol M12 x 100 2 B5358129AA v Lowe wshbone assembly L/H 1 M3551048AB v Lowe wshbone assembly R/H 1 M3551049AB Pocedue 1. Offe he lowe gh hand wshbone assembly o he mounng pons on he Rgh hand fon of he chasss as llusaed. 3. Secue he fon fxng o s chasss mounng pon usng a M12x1 00 bol, hee washes and a Nyloc nu n he posons llusaed below. Nu hasss moun poson Bol Ensue he ball jon s ponng up wads. Noe he fon fxng s suaed a he end of he longe am. Rea fxng. Dung hs pocedue, oae he nus ono he bols unl he head jus begns o be no he nylon. Do no fully ghen. Toque sengs and seup ae descbed afe he elave engne nsallaon. To ensue seps 2 and 3 have been followed coecly, ensue he bol head on he fon fxng faces owads he fon of he chasss and he bol head on he ea fxng faces owads he ea of he chasss. Fon fxng. 2. Secue he ea fxng o s chasss mounng pon usng a M12x90 bol, hee washes and a Nyloc nu n he posons llusaed below. Washe posons To ensue hee s no sdeways play (end floa) n he nsalled wshbone, he followng pocedue mus be opygh Bkn as (Py) Ld
appled: a. Sandng decly n fon of he chasss, fmly pull he wshbone owads you. opygh Bkn as (Py) Ld
Lowe Wshbone Pocedue con. b. Sll pullng he wshbone fowad, vew he fon fxng fom above o ascean whehe o no a cleaance exss beween he wshbone and he chasss as llusaed below. If such a cleaance does exs, s mpoan o ake up wh he exa 12mm fla washe ha s suppled. 4. Repea he pocedue sang wh sep 1 fo he nsallaon of he lowe lef hand wshbone. opygh Bkn as (Py) Ld
3:2 UPPER WISHBONES - K3601022AB omponens n hs assembly Qy Pa Numbe I Bol M12 x 60 2 B5358055AA Bol M12 x 65 2 B5358056AA Bol M12 x 95 2 B5358058AA v Nu M12 Nyloc 6 B5358060AA v Washe 12mm Fla S/S 14 B5358061AA v Uppe wshbone 2 M3551050AB v Wshbone shock space 2 M3851015AA I s advsable o f he fon shocks whle fng he uppe wshbones. Bkn ecommends ha OE (ognal equpmen) shocks and spngs ae fed. Engne ype and desed seup wll deemne he spng ae. Fo nfomaon on spng aes and seup, please conac you Bkn agen. K3601258AA - Shock Absobe Assembly. Zeec, avalable n Goup 10 - Oponal Exa s, have been used n hs pocedue. Pocedue 1. Offe he uppe gh hand wshbone assembly o he mounng pons on he Rgh hand fon of he chasss as llusaed. Ensue he ball jon s ponng down. Noe he fon fxng s suaed a he end of he longe am. 2. Secue he fon fxng o s chasss mounng pon usng a M12x60 bol, wo washes and a Nyloc nu n he posons llusaed below. Do no fully ghen any of he wshbone bols dung hs pocedue. Toque sengs and seup ae llusaed afe he elave engne nsallaon. Befoe he shock and spng assembles ae nsalled n he seps ha follow, s mpoan o noe he dffeen fxng pons and he locaon of he shock adjusmen conol as llusaed below. opygh Bkn as (Py) Ld hasss moun posons Uppe fxng pon Adjusmen conol Washe posons Lowe fxng pon
Uppe Wshbone Pocedue con. 3. Usng a M12x95 bol, hee washes and a Nyloc nu, f he uppe fxng pon of he shock and spng assembly and he ea fxng pon of he wshbone o he chasss When nsallng shock assembles, ensue he Shock adjusmen conol s facng owads he chasss. Ensue ha he heads of he bols nsalled n seps 2 and hee ae facng he fon of he chasss. hasss moun posons Bol Adjusmen conol Washe posons 4. Usng a M12x65 bol, wo washes, a shock space and a Nyloc nu, f he lowe fxng pon of he shock and spng assembly o s mounng pon on he lowe wshbone as llusaed below. Nu Wshbone moun posons Bol Washe posons 5. Repea seps 1 o 4 fo he nsallaon of he lef hand uppe wshbone.. opygh Bkn as (Py) Ld
3:3 STABILISER BAR - K3601023AA omponens n hs assembly Qy Pa Numbe I Bol M8 x 60 2 B5358085AA Washe 8mm fla 2 B5358088AA Gub scew M6 x 6 2 B5358125AA v An-oll Nylon bush 2 B5451185AA v An-oll ba 1 M3401 162AA v An-oll ba mounng block 2 M3801001AA v Locang Boss 2 M3851058AA Pocedue 1. F he Nylon bushes o he md secon of he an-oll ba as llusaed wh one bush below. 3. Place he machng pas of he mounng blocks aound he nylon bushes wh he non-headed block neaes he fon of he chasss. The bol holes mus s below he an-oll ba. 2. aefully feed he an-oll ba hough he cu ou below he uppe wshbone fon mounng pons. Ensue he ends of he anoll ba pon owads he ea of he chasss. The an-oll ba mounng blocks ae mached pas, denfed by samped numbeng howeve, he wo halves ae no dencal. One of he halves has a headed bol hole. Samped numbes 4. Secue boh pas by placng a M8x60 bol complee wh a washe hough he chasss and he nonheaded bol hole of he fs block. Roae he bol no he headed bol hole of he second block bu do no fully ghen. opygh Bkn as (Py) Ld
5. enalse he an-oll ba o he chasss by ensung equal dsances fom he cene pon of he bol heads, secung he ea fxng pon of he uppe wshbone, o he ends of he an-oll ba. Toque he mounng block bols o 34Nm. opygh Bkn as (Py) Ld
Sablse Ba Pocedue con. 6. Place he wo, M6x6 gub scews halfway no he locang boss s. 7. Slde he wo locang boss s ove he ends of he an-oll ba unl hey es agans he mounng block bushes hen fully ghen he M6x6 gub scews. opygh Bkn as (Py) Ld
3:4 UPRIGHTS - K3601286A omponens n hs assembly Qy Pa Numbe I Nu M10x1 pch 2 B5358034AA Washe 10mm fla 2 B5358132AA Upgh assembly L/H 1 M3551071AB v Upgh assembly R/H 1 M3551072AB v Bake ppe mounng backe 2 M3101038AA All oque sengs of bols and nus as well as beang pe-loads on he upgh assembles ae se befoe delvey. Do no adjus anyhng on he upgh assembles unless saed n he pocedues ha follow. The ball jons ae pe-algned fo upgh nsallaon befoe delvey howeve, ncase of ms-algnmen dung shpmen, s essenal hey ae checked and, only f necessay, ealgned wh he followng pocedue. Algnmen Pocedue The ball jons on he lowe wshbones ae coecly algned when he sagh lengh of he R-clp s pependcula o he sablse ba lnkage mounng pons as llusaed o he gh. The ball jons on he uppe wshbones ae coecly algned when he sagh lengh of he R-clp s paallel o he ball jon suppo bol asa llusaed o he gh. Realgnmen 1. Remove he R-clp, casle nu and washe fom he ball jon. Replace he casle nu and oae n a ghenng moon unl eaches he end of he head. Replace he R-clp and hen, usng a 17mm spanne, un he casle nu unl he R-clp eaches algnmen. Realgnmen 1. Remove he R-clp fom he ball jon hen oae he casle n a ghenng moon unl eaches he end of he head. Replace he R-clp and hen, usng a 17mm spanne, un he casle nu unl he R-clp eaches algnmen. opygh Bkn as (Py) Ld Insallaon Pocedue The upgh assembly has an uppe and lowe mounng pon as llusaed gh. Uppe mounng pon The lef hand and gh hand upghs ae deemned by he poson of he callpe. Eg. The calpes, when nsalled, mus face owads he ea of he chasss as llusaed fa gh. Lowe mounng pon
Upgh Insallaon Pocedue con. 1. Remove he R-clp, M10 casle nu and washe fom he gh hand lowe wshbone ball jon. 5. Place he gh hand upgh assembly s lowe mounng pon ove he head of he lowe ball jon s bol. 7. Replace he washe and he M10 asle Nu. Tghen o 6Nm and hen fuhe ghen unl a casle slo algns wh he hole fo he R clp. The R clp mus hen be nseed. R-clp housng 3. Remove he R-clp, M10 casle nu and washe fom he gh hand uppe wshbone ball jon. ) y Upgh poson 6. Replace he washe and he M10 asle Nu. Tghen o 6Nm and hen fuhe ghen unl a casle slo algns wh he hole fo he R clp. The R clp mus hen be nseed. 5. Slde he gh hand uppe wshbone ball jon bol no he upghs op mounng pon. 7. Repea seps 1 o 6 o nsall he lef hand upgh assembly. P ( s a d L Upgh poson n k h g y p o B The emanng Bake hose mounng backes, washes and M10x1 pch nus mus be soed n a safe place unl he adao s fed n Goup 5.
3:5 FRONT STABILISER BAR LINKAGE - K3601183AB omponens n hs assembly I Qy Pa Numbe 2 2 2 B5358062AA B5358092AA M3101006AB M8X30 ap scew M8 Nyloc nu Lnkage assembly The Upgh assembles wee emoved fom he chasss fo he sake of phoogaphy only. They ae no o be emoved fo he nsallaon of he lnkage assembles. d L Pocedue The lnkage assembles have wo mounng pons, an uppe, and a lowe ose jon as llusaed below. The wo ose jons of a lnkage assembly ae algned a nney degees o each ohe befoe delvey. Ensue hs s sll he case befoe nsallaon. P ( s a Uppe Mounng Pon n k h g y ) y 1. Usng a M8x30 cap scew and Nyloc nu, secue a lowe mounng ose jon beween he lnkage ags on he lowe lef hand wshbone. Ensue he cap scew s head faces owads he fon of he chasss hen oque o 11Nm. B Lowe Mounng Rose Jon p o 2. Slde he op mounng pon of he lnkage ono he an-oll ba unl measues 10mm fom he end hen ghen he cap scew by hand. 10mm Vewng he lnkage fom he fon of he chasss, ensue he followng. The cleaances beween he uppe ose jon and he mounng backe ae equal and paallel. The complee lnkage assembly s paallel o he shock and spng assembly.
Fon Sablse Ba Lnkage Pocedue con. 3. Usng a 5mm allen key, fom hand 4. Tghen he lock nu, locaed on gh, ghen he cap scew a fuhe he cap scew, agans he mounng ¼ un. backe. 5. Repea seps 1 o 4 o connec he second lnkage assembly o he gh hand sde lowe wshbone and anoll ba. Ove-ghenng of he cap scew may cause he head n he mounng backe o sp. P ( s ) y d L ycle Fende Aachmen Pocedue Ths pocedue should only be execued afe he cycle fendes have been paned. a 1. Slde one of he M5x20 washes, emoved fom he mounng plae n Goup 1, no place ove he sud hole beween he plae and s enfocemen. n k h g y p o 3. Afe posonng a second M5x20 washe ono he vacan sud, eplace a M5 Nyloc nu ono each sud. 2. Sll holdng he washe n place, poson he mounng plae wh s ubbe space ono he headed suds ha poude undeneah he cycle fende. B Tghen he Nyloc nus by hand unl he head jus begns o feed no he nylon of he nu. I s essenal fo he aachmen of he cycle fende o s mounng backes ha he mounng plaes eman loose. Repea seps 1 o 3 fo all emanng mounng plaes. The slaned edge of he cycle fende mus pon owads he fon of he chasss.
ycle Fende Aachmen Pocedue con. 4. Remove he M8x25 domehead scews fom cycle fende mounng plaes hen slde he mounng plae suds no he sleeves of he cycle fende mounng backes aached o he upgh assembles. 6. Tghen all he M5 Nyloc nus unde he cycle fende unl he head poudes he op of he nu by 1mm. 5. Usng a 5mm allen key, eplace and ghen he domehead scews. P ( s a n k h g y p o B ) y d L