Koni front inserts into a Mighty Boy
Posted: Mon Aug 19, 2019 12:16 am
Koni - Adjustable inserts into a Mighty Boy
Koni special Part No 86-2400
Check bottom of strut, if there is already a bolt head you are a winner. Strut mod already completed.
If not, the strut is standard. in photo left strut has koni inserts, right is standard. I am not a mechanic, the following is what I did to install the inserts using Koni instructions and some trial and error.
Use this post for general overview and if your not confident maybe take it to a suspension expert.
Use spring compressors if needed to take pressure off the top of strut to allow you to undo top bolt.
If the spring is still under tension and your nut is at the top of the tread fully engaged,you will need a spring compressor.
I didn't need to as king springs KSFL-12 had zero compression when fully extended.
Place all the parts in order on the table. Wrap strut with a thick rag and place in vice upside down. GENTLY hold strut in jaws, do not crush the tube.
Centre punch bottom of strut Put on safety glasses especially if you have a gas strut. Mine was oil only so not too exciting.
Drill a 4mm hole through the bottom.
Drain oil into bucket, open and close strut a heap of times and shake to get most out.
Next cut the strut tube just under the top seam weld. Use a hacksaw, angle grinder or metal band saw.
You only need to cut the strut tube not the central shaft which is hardened steel.
Its only about 2mm thick and pretty easy, cut as straight as you can but can clean up after with an angle grinder.
Once cut, pull out the old shock, pour remainder oil into bucket and put a rag in the cut end.
Turn upside down and drill the 4mm hole on the bottom of strut into a 13 – 14mm hole.
Koni asks for 14mm but 13mm is fine if your hole is pretty central.
Tidy up hole and the cut tube with a file
Paint hole and cut to stop rust
Slide Koni strut into strut tube and push in.
Koni special Part No 86-2400
Check bottom of strut, if there is already a bolt head you are a winner. Strut mod already completed.
If not, the strut is standard. in photo left strut has koni inserts, right is standard. I am not a mechanic, the following is what I did to install the inserts using Koni instructions and some trial and error.
Use this post for general overview and if your not confident maybe take it to a suspension expert.
Use spring compressors if needed to take pressure off the top of strut to allow you to undo top bolt.
If the spring is still under tension and your nut is at the top of the tread fully engaged,you will need a spring compressor.
I didn't need to as king springs KSFL-12 had zero compression when fully extended.
Place all the parts in order on the table. Wrap strut with a thick rag and place in vice upside down. GENTLY hold strut in jaws, do not crush the tube.
Centre punch bottom of strut Put on safety glasses especially if you have a gas strut. Mine was oil only so not too exciting.
Drill a 4mm hole through the bottom.
Drain oil into bucket, open and close strut a heap of times and shake to get most out.
Next cut the strut tube just under the top seam weld. Use a hacksaw, angle grinder or metal band saw.
You only need to cut the strut tube not the central shaft which is hardened steel.
Its only about 2mm thick and pretty easy, cut as straight as you can but can clean up after with an angle grinder.
Once cut, pull out the old shock, pour remainder oil into bucket and put a rag in the cut end.
Turn upside down and drill the 4mm hole on the bottom of strut into a 13 – 14mm hole.
Koni asks for 14mm but 13mm is fine if your hole is pretty central.
Tidy up hole and the cut tube with a file
Paint hole and cut to stop rust
Slide Koni strut into strut tube and push in.