SKODA 120 LSE 1980 Workshop Manual

(
t
t
s r
1
S
t S
n
o
fl
p
t\
e
g
tl
St
T
o
e
ir
h,
el
r€
re
5. Ploce
the steering
box with its bottom
boll
beoring resting on the MP 7-102 jig
ond press
the steering screw
with both beorings into the
iig. Extroct the
bottom beoring using
the MP
6-111 king pin
socket remover
ond push
the
steening screw with the top beoring oert of the
steering box. Support the beoring by the Mp
7-102 iig crnd
press
it out.
7.3 REASSEMBLING STEERING BOX
1. Press the dust cup with its seoling
ring
into the steering
box with the pressed-in
bush
ofter hoving thorouchly
cleorred the box. Now
pf oce the box on the MP 7-102
iig oncl
press-in
the bottom boll beorinct
using tlrei pressing
mandrel MP 7-103.
2. Fit the lower beoring
cop seoled
off with
o poper
gcsket
ond seoling compound, slip
lpring woshers
on to the bolts,
ond tighten the
bolts with o torque os per
Chopter t.6. f it the
wosher on the steering screw
with its deflec-
tion focing
the screw threod ond press
the
top beoring on the screw
using the Mp Z-103
pressing mondrel.
3. Then ploce
ogoin the steering box on the
MP7-102 iig ond
press
into it ond into the bot-
tom beoring the steering
screw with the pnessed-
-on top boll beoring,
using ogoin
the Mp7-103
pressing mondrel. For further ossembly, use the
vice ond the dummy brocket.
Fig. 7.311 -
Pressing-in Bottom
Beoring
on MP 7-102
Jig (support
plote)
Using
MP 7-103 Piressinq
Mondrel 4.
Meosure the height of the beoring pro-
truding from the steering box ond odiust it by
fitting shims interspoced with poper goskets
cooted with o seoling
compound.
Fosten down
the cop by tightening the bolts. Check the
steering screw for free rototion
ond the obsence
of ploy.
The beoring should be without o cleor-
once or there hos
to be o prestress
of up to
0.07 mm.
5. Remove the bolts of the cop, slip the rub-
ber seoling ring dipped in oil on to the shoft,
ond fit the dust cup on the cop. lnstoll spring
woshers on the bolts. Should the cup be over-
stroined due to the toleronce
of the recess for
the seoling ring or the ring itself
, instoll
o poper
gosket under it os under tlre ccrp.
6. Locote the steering nut on the screw fol-
lowecl by the rocker shoft with pin, spring,
spring pin, ond the licl gosket
cooted with
o seoling compound, ond fit the lid with bush
in position to close the steering
box. Instoll
spring woshers under the bolts orrd tighten the
bolts with o torque os per
Chopter 1.8. Screw
the set screw into the lid ond rnove
the steer-
ing geor
so thot the drop orrn is swivelled
through obout one holf of its trovel from the one
or the other extreme lock position.
Witlr the
drop ornr in this position,
screw down the set
screw os for os it will go
ond then bock it off
through obout 95 to '120'.
This will provide
for
on odequote cleoronce of the steering geor.
[.ock the set screw in position
with the re-
spective nut.
7. Drive the key on to the rocker shoft cone,
fit the drop orm ond hold it down lightly with
the nut. Clomp the drop orm in o vice, tighten
fully the nut (for
the tightening torque see
Chopter 1.8), ond secure tlre nut with o cotter
pi n.
8. Clomp ogoin the steering box by meons of
the dummy brocket ond moke sure
thot the dnop
orm con swivel from one extreme lock position
to the other. A certoin
resistonce should olwoys
be present,
but if the resistonce is too greot,
decreose it by o slight slockening of the set
screw in the lid. The
rototing resistonce of the
shaft should not exceed 20 Nm (O.2
kpm). Refer to
page 117/118 for testing
procedure.
9. Set the ossembled steering box in its fit-
ting position
(inclined
by obout 40o) ond pour
in oil through the hole in the bbx lid (cover)
till the oil level reoches the bottom edge of the
filling hole. Then
screw down the topered plug.
7.4 RELAY (TDLER)
LEVER
For its instollotion (ond
removing in reverse
order) ond ony pertinent porticulors
see the
Chopter 6.5, porogrophs
2 ond 3.
122

ez,
e6olull 6u1:ee1g ;o
luaulsnlpy puo
Ilquessv -
L/g'l'6!l
puo lcoqc puo
leeqM 6u1ree1s eql e^ousu
'l.rossaceu l! 'ecuDls!p
ulDuec
rDc aLll 6u111o.r lq uo;11sod s!tll
loeqC 'la^Drl
uorlcarlp sql u! lrl6!o.rls sleeqM eq] ecold
o1
urnl puD
UDLIs eql
uo
leeqM 6ug:ee1s
oql
r!J
6u;11;;eg
'leeqM 6u1:ee1s eql eerl 1.re! .ro
llnd 'lnu
llDqs uLunloc 6u1:ee1s oql
,lo MaJcs
puD
pnoJqs
e>1ods eql iorvto l;g; 'selods
leeqM 6u1.ree1s eql
;o lrod ruolloq
oql uoJl
sMeJcs oMl a^ouau
lD^otueu
13f H/Vl
eNtu:tfrs t'L
'(6u1ue1so1 puD uollDcr.qn1)
looq lsnp eql
6u1co1de.i uoqM
errDs aql s! eJnpaco:d eq1
'pJoMJo'
Jo prDm)icoq
sscot
l! fDql os ''e'r 'lelcos
oql
lo au!l orluec
1ou1pn116uol aql
ol .ro;nclpuedlad
lnoqD i;r
tiols sli
lDql os
pallDlsug
6u1.r >lcol D
qllAr sla:icos orll ol slooq
tsnp aql
.LlcDllv(g qdo.r6
-urod '9"2
iaidoqg) spor
6ug;ee1s 6u1;queso
-ar uolt;\A slu!o! llDq lo uolloclrqnl
aqt rol
ragdnulc snotna;d €r.ll u! papusuJurocer
sasoar6
aql dlenlsntrcxe 6u1sn 'i.rosseceu
lr luDctJqnl eql
dn do1 "(1e>1cos
eq] uoJl
looq lsnp eql
e^ouer
'6u11ooqc rol) luoct:qnl D
ql!M
A1:edo.rd pallt+
st
:! | ]Dl.li 'xtun
Msu aqt 6urtilleJ eloleq 'elns
a>lotu
'u1d 1;oq €ql
qllM
lelcos o 6u;co;der uell71n
'('c1a 'ssau1q611
-.ra1orur) uo!soJroo 1su1o6o uoglcaloJd
o so peltnb
-a.i s! luDclrqnl D
tnq lolrelDu 6u11ocglqn1-lles
D
qlr,tn porl!l
ero sloes u1d-11oq eql'l!un alqDlqLUes
-sBslpun uD s! lelcos sl!
q11m
u1d
llDq aql
s.!_oo8 tsno oNv
sNld l]vs 9'L
reLlseM de1 e qlrnrr
lnu aql
lcol pue
[uN
0g -Oglo
anbrol e 6ursn Jolcauuoc eql uo
lnu IOol eql unnbp
^
orcs uotll 'sqlg'V66\Z
st uorltsod 1se.t
sy uJorl po.t
6uuaegs eql 0urtcallap rol parrnbar
pue peorql po.r 6uueels oql uo 6urlce (actol)yoga
oql leql os
rolceuuoc po:
Icell aql ua1q611
'ruru L+6tt rrelaMoLl
'oq plnoqs sugd
lgoq eql uaaMloq
la)cos po:
6ur
-Jeals eql
lo acuDlslp aql 'por
l3DJl oql
lo pua
Jeqlo aql o1 sa1;ddo alnpaco.rd suDS eqf 's
'su1d 11oq aq]
ueeMtaq LUtu
L Tgge lo
ocuDlsrp D lo eq
plnoqs
lelcos po.r
6ur.reals aql
'por 6ulraels eql lo pue pepoorrll
eLil uo
]e)30s
poJ 6u1reels puo
lnu eql uMop MeJcS 'v
'poJ lcDrl sql
lo le)cos eql ol uo uaql
MeJcs nnop 's1:od
eql lo Jolralu!
aql oslD esoer6
q11m 6u11cod '(0t
ssoere L'J d!6V ro '[A-]
esDe
-lorlsDC '71
asoer6rau3 'tC6
ro dW esoa.r611qo61
'V xoultau lleqS) esoe:6
qtlm
lelcos u!d
llDq eql
puo 'rau!l
lelcos por
lcDrl oq] 'llDq
por
lcDil eql elDclJqnl 'Alquessoal
ileql eJolag 't
'por lcDrl eql ol uo
looq lsnp lu!ol le>lcos-puD-lloq aql
q]!M
rolsau
-uoc por
)cDll eq]
puD
rau!l
lelcos aql dlls 'z
'PoeJql eql 01 uo JeqsDM qD]
D q}!M
Jnu D /!^er3s
puD leloos por
>lcoJl .re6uo; eq]
+o aloq eql
olu! lalcos u1d
11oq eql
llDlsul 'aor^
D u! slo)cos
uo-passe:d qllM
por
lcDr] aqt duo13 'L
lueurlsn!py puo
Alqtuessoeg
'srDc 0LL/001 puD
Bht 0001
Dpols rol pesn
renouer
t0L-9 dl l aLll
,o uo!sre^
paueuoqs D s! Je^oureJ
8tL-9 dl^ srll
:eloN
'sdnc .reqqnr aql ropun
Algsoe drls uoc ieql
lDtll os
l!o qllM
ranouer eql
lo sr"ro! eql
1oo3
'uo11gsod 6u;1puoq
elqDl!ns lsou eq] o1u1 :oeB 6u1.rae1s eql
les
'u1d
1;oq ulo do.rp 6u1:ee1s aql uo'renotuer aq1
Duttttl orolaB 'ra^oruar
8tl-g dt1l eql
lo pro
all
qll'\,[ a6Dlu!l aql
lo lno suld
11oq aq1
qsnd puo
su;d ;;oq lo slnu
aql o^ouler puD
lcolLrn 'Z
'laeqM a:ods eql
lno elDI'L
JDC u! 6u1g;1ag puo
luort
lDnorueu
D
lo l!
L',t"s't fov)Nr] eNrussrs
9'te
'6
eI (r
JN
-tl
ol
eq
lal
,ID
sIr
.uo do
jo
JAI
oa:
ual
ql!
'ou
-eJ
.JD€
Jo]
tro
les
eql
auo
pall
-JSa
/!\EJ
oql llDl!
qsn(
qltr
'6u!.
'toJ
lado
Jol f
-JAA(
6ut.rr
'1,Dq
'qni
o1 dr
-JDeli
acue
eq]
uMoF
slo{s
Aq lt
-o,rd

7
.7-1.8
(
t
t
t
; (
(
b
tl
ir
tl
p il
o
tl
p
odiust,
if necessory, the driving dog of the di-
rection indicotor switch -
see Chopter 13.17.
Refit the steering wheel so thot its spokes
ore horizontol, lock it in position
with the nut
(for tightening torque, see
Chopter 1.8), ond
bolt down the spoke shroud.
7.8 STEERING WHEEL SHAFT AND SHAFT
BEARING
The steering wheel (column) shoft is built
up
of two ports
with the beoring in the uPPer port.
Usuolly, it is not necessory to disconnect the
two ports
of the shoft or to remove the beoring
ond steering lock. lt
con be removed from the
cor os o unit.
Removol 1. Remove the steering wheel -
see Chop-
ter 7.7. 2. Remove the screws on the lower port
of
the shoft cowling ond pull
the cowling off.After
removing two bolts, detoch the cluster switch
on the shoft from the upper port
of the shoft
cowling. 3. Remove two front screws of the upper
Port
of the cowling ond remove the cowling.
4. Disconnect the leods
from the switches
ond the switch box.
5. From under the cor, remove the bolt of the
coupling connecting the steering
column shoft
to the steering box ond detoch the dust boot
from the floor. Remove the
bolts of the shoft
beoring (from
under the shoft)
ond the bolts of
the steering lock (from
the front) fostening the
shoft to the body, ond pull
out the shoft.
Ref itting To ref it the steering column shoft
in the cor,
reverse the removing procedure. While reinstol-
ling the steering wheel (Chopter
7.7), do not
forget to check the direction indicotor switch
for correct function.
Use ploin
ond spring woshers under the bolts
of the steering lock
brocket. Reinstoll the shoft
beoring using spocing tubes, rubber bushes, ond
ploin woshers, ond secure the bolt of
the coup-
ling, connecting the steering
column shoft with
the steering box, with
o self-locking nut (for
tightening torque, see
Chopter 1.8).
To Disconnect Shofts
Remove the bolt
of the cross-pin
ioint con-
nection.
Connecting of Shofts
Fit o fostening sleeve on the tube
with the
shoft, dip the ring in oil ond slip
it on to the shoft end with
its wedge-shoped port
toword
the beoring, instoll the spring
ond the
ioint
socket of
the shoft bottom port.
Tighten
the
connection with the bolt with self-locking
nut
(tightening torque os per
Chopter 1.8).
The sleeve must be f irst built up if
the shoft
is refitted for the first time. Locote
both holves
of the sleeve on the tube ond fosten
them
lightly together by bending the tob of one holf
of ttre sleeve over the
other. The
sleeve must
on no occount clomp the tube tightly.
Bottom Port of Steering
Column Shoft
The shoft is provided
with cross-pin
ioints
ond connot be dismontled (token
oport). Before
fitting the shoft dust boot, smeor
it with
oil to
focilitote its slipping over the pcrrts
of the joint.
For this purpose,
it is clso odvisoble to wrop
the joint
in o plostic
foil or to moke o sleeve
with o pilot
cone.
Top Port of Steering Column
Shoft -
Beoring
Removol 1. l-ift owoy the fostening sleeve
ond check
whether the shoft rototes
freely in the tube. lf
it is not the cose, unlock the steering lock ond
press out the shoft proceedirrg
from the side
of its splined
end.
2. lf necessory, remove
the circlip of the shoft
ond lift owoy the beoring. The other beoring
hos to be driven out by topping it corefully
through the cut-outs in
the tube to ovoid domog-
ing it. 3. Remove the brocket with the steering
lock
- see Chopter 7.9.
Ref itting
1. Slip tlre beoring pocked
with greose
on to
the upper port
of the shoft, then the ring with
its wedge-shoped port
focing the beoring, ond
lock both ports
in position
with the circlip.
Press the shoft into the tube ond press-in
the
beoring (ogoin pocked
with greose)
from the
other end.
2. lnstoll the brocket with the steering lock -
see Chopter 7.9.
Shoft Beorings They hove to be thoroughly lubricoted
first,
since ofter their reossembly with the shoft od-
ditionol lubricotion is not possible.
lf there is
ony doubt concerning the greose
pocking,
re-
move the circlip f
rom the inner port
of the
beoring, toke the beoring oport, cleon it, ond
reossemble it ofter hoving pocked
it with the
recommended greose,
i. e., brond NH2 of Cze-
choslovok provenience
or one of the bronds
specif ied in Chopter 7.5, porogroph
3.
124

9er
lloq 6u!ualsDl
lcol 6ug.raa1s
-
y
'xoq tlcllms puD
>;co1 6ulraals -t 'lelcDrq
lcol
6u1.ree1s -
7 'UDrls
uurnloc Dugleals
Jo eqn]
-
L
lalcolS u!
1co1 6u;.raols
lo 6urue1so1
-L16'l'6t)
'llo sloorq
poeq sl!
ll!r lloq eq1 ue1q6g1 'uo!l!puoc
gce;.red
u1 s1 .roe6 6u1rea1s
ol!]ua aql
lDql peulDyecsD
6u;noq rego
A;uo
Allnt
rloq aql uelq6ll '1e1corq
s]! ul
lcol 6u1.ree1s aqt
6u!llotsu!er ueq471
'loAouIeJ lloq lol elqo
-llo^o (re;1nd pDeJql
o ro adoqs ro;n6uo1ca;
;o
6ed) gool
erll
lo suolsueulp aql ol
ll u! eloq
D
lllJp ol lrossaceu s!
l! lloq eql e^ouer ol
'6u1iee1s eLll |o 6u11puoq
lnlacrol luo apn;c
-erd o1 poeq
llo-Ioorq D
qllM
lloq lolceds o
Aq
lelcorq aql ol
peuelsDl
s!
ll 'xoq
qcllMs aql puo
ipoq >1co1
aql
lo slsrsuoc >1co1 6u;leels
aql
>;co1 6u;rea1g
',,rco-l
6u1ree1g, qdo.r6o.rod
lxeu eW
sas
lool srll ;o
6u1uelsol Jol 'slusuodtuoc
1;oqs puo
s1.rod
pe^ouer eLll
'o Alquassoe.r
eqt eleldtuoC .g
',,lco-l 6uglee1g,, qdo.r6o.rod
]xeu eql
oss 'lloq
aql io 6urua1q6;1
llnl rol 'uoglolado
sl! lsel puo 'lloq
eq1 6urualq6rl A11q6r;s lq
1r
uelsol 'lelcorq
aql u!
lr llolsuter '(q
qdo.r6o:od
rad so) pa^orilar
ueaq sDq
lcol aql Aluo
;1 .7
'uolloledo ee4-qol!tl roJ lcol eql
lceqC'6u1>1co.r puo
6u;qsnd{q aqnl
Uoqs aq} ur
eloq eql ra^o
lcol 6u1;aa1s
eql qlllln
lalcDlq eql
anou puD 'aqn1
1;oqs eql
lo pue
eql puD
lelcDrq
or.l] u! s6u1.r .reqqnr eq]
l!o r1llm
rDauS 'L
(uurngo3 6u;raelg
)
rtoqS uo
lco'l 6u;reelg
6u;1;o1su1ey
',,lco-l 6u1.raa1g,,
qdo$o.rod 6u1mo;1otr aql ul peqlrcsap
sD
)col
aql a^ouroU 'lloqs
aql lo s1.rod
.rarvrol eq1
puo .reddn eq1 alorodes puD '1u1o!
uqd-sso.rc
eql Oullcauuoc qoq
aql puD
Uoqs aq]
lo
1.tod reddn
eq1 Bu;uelsDl slloq
rnol eqt e^ou.r
-eJ 'pelcolun
aq louuoc )col 6ur:ae1s
aq]
ll (q
'oJl puD ol
1g 6ug1co.r
el!qM
tlDqs eql
go
)ool 6ug.rea1s
sql qllM
lelcDrq eq1
11nd puD 'l!o
qllM pue
UDLIs aql Joorus '>;co;
6u1rcels eql 1co1un (o
(urun;og 6u;reelg)
rtDqS uort
lco'l 6urlee1g
6uqnouaX
.lrom{poq aqt
uor, laloorq lcol 6u1:oa1s
aql qcolac '(qc11rurs
rolDo!pu! uo!lcoJ!p puD 'V
ol ; sqdo.r6o.rod
'llDqS loaq6 6urraelg 6u;notuaS) 'g;
.ra1doq3
puD 8'l reldoqg aes
)col aql
o] ssecoD roJ
-\-
-1\
--
>|co] eNtufSls 6't spr
-ezi
aql pur
eqt
-eJ
s! r
-po
'lsJ
-t
etlt
eql
'dlt
purt{l !
ol
rc(
-6o
Allr
6u!
lf ot
ep! Pul
Jl '
rc€
aA€
dor 'lu!
ol eJo
slu
lsn
,lor uIo
sel
UDI
lnu
eql
lu !(
prd

LZI
sreqrosqv lcotls t'8
s6ulrds rDeU
Z'8
6ZL s6ulrds
luorJ L'8
6ZL
e60d uolld!rcsac
loc!uqcel
0tr
6ZL
sulguosgv )coHs
o Nv
NOISNldSlls-8

6Zr
(ra11o1su1 6uudg) 6rp
p!V eql qllM
6u!rdS poou 0LL-S
dtA aqt jo
6urnoua6 -
LIZ'g'6lJ
'pod aq] ut sssacar
aq] olu! slrj
ltoc 6uuds
aql jo pua
aq]
loq]
os 6ur.rds
alll o1 uo ueq] >1cr1s '6uuds
sql lo
6ug11r;a.r 6urrnp spod :eqqnr aql
,o 6urco;dsrp
eql luenerd o1 '6uilds
aql 6Lr!lttla.t ]o einpe3
-o"rd aql oslD sr srrJf 'alxD
aLll urorl panoura_l
aq UDO 1! ll!] l! Ltallorls
o1 6ur.rds er,11 sse.rduoc
'rloq 6!! aq1 6ururnl Ag 'qloeurapun
ruo-rl sl!o-l
ssorc eql otrur
]loq 6t!
aqt Mercs puo 'a;qrssocl
sD uraLll ol lDeu so -ro 6uuds
aql jo
sltoo pua
aql ueeMleq 6tl eql
lo sltDr ssorc
aq]
llDtsul
'raqlosqD
loor.ls eql
puD '(6urlpuoq
lue!ueluoc aJoul io1)
leaLlM eLll
enou.tel ,a1oA
uorsuedsns eql ol uo sdo.rp qclqM
elxD-lloq
rDei aql elerlal o] sp os Apoq
aql
lloddns puo
ioc eql dn
lcop '(-re11o1sur
6urrds) 6tl
Oll.S .ty!
erll osn'6ur-rds aql
l!]ar puD
aAorua.r ol
6ur11r;aX puo 6urnouoS Bur.rdg
81.116 |
!n real
;'g ra1doL13
puo uotJoct]tssDlc eql Jol
aas 's6ur.rds
lo osn 'g'g
puo tg sreldoqS
eas 's6uuds
;o 6ur111;eJ
puD
lD^orueJ aql
JoJ
uo 8t6 I 816 r -916
r
'6ur6ur.rds ueAaLtn Lr I
llnse.l
ol ldo sr
.,t1uo 6u1.rds euo
Jo lueuieco;dal puD
lDlrelou oq]
]o en6rlo,t
ot anp ua)DeM s6ur.rds
poor eql'aru!l
]o rll6uel
o reUV
alxo-JrlDq
Jeqlo eql yo
6u1rds aq1 oslo acolder'a^rloa]
-ep s! elxD-ilDq euo
lo 6ur.rds
aLlt
ll '-rDc
D uo
ssolo aruDs atll
lo s6ur rds
ltl ol
lLrDl.todrur sr
11
pu3 lloc eql roaN oarv
troll pLlnoro
D
]o suDol/\
Aq s6uudg .ra6uo.r1g
lo uortoc!]rluapl
-
L/t'g'6!J
otf xo
.L/L'B
'69 ul uMorls sD pa)roru
arD ssolc .ra6uo-r1s aq1
1o s6ugrdg '(atqof
anrlcadse: aLll aes) sassolc
Jo sdnolD oMl olu! pepl^lp
eq iroc
s6uuds
pDoJ sql 'secuora;o1
uorlcnpo.rd puD
(ql6Lra:is)
senlD^ ec:o; 6urssa.rdr-uoc Jraql ol pro6ar
r;t!M
esn rlot{I puo
sOulrdS
lo uorlDcrllssDlC
srlnoJpAq eql
lo
uorlcas-punor loscNtuds
rNouJ r'8
'adA] crdocsalal pLrD
ero sreqrosqo
l30qs oLll 'ejrM
papoc ero s6ut.rds pDoJ
arll
uo;1d!JcsaC losruqcal
l/l86tJ
I auop
t/ 18
UU 98I UU
S6I
" ,.1i otoo
I *
tu
L- otoo
^, 0- orot
'' q6 t+ ,,96r-
01Ot
'H -uo3
rol painos,
uoga) aJoJ
9LZ uw
1+t8z qrbual
aerj
t0l eorrelausrp
rarno 6urdS
WU E'Z UU
9 ZI
I'ls6'l I ruoN
I i8
a UU
'€Z lo
qr6uat e ol 6u rds
aql 6! ssarduor rol
parnbar 1!otelatrrol
N
1il+ Os6r
lr.o- OSci r |
096[
G N
o
0s6e
Nltt- o96e
9lt rtt
9 raraue
prarno
6!udS
UU 9I
er-i s SONIUcIS
UV:IU Z'8

Shr
C
cle,
the
1
fittr
bor
(Im(
2
wit
woI
pisl
wor
the loc<(11,
3.
obo (M(
I nst
rod
the
oil' into
4.
witt
Con
prot
Inod
On f(
Inodr
oll c(
Excer
on c(
8.3 SHOCK ABSORBERS
The shock obsorbers ore of
the hydroulic,
telescopic, double-octing type of the PAL
moke.
The domping effect depends on the speed
of the
relotive movements of the oxle ond body. Doto
required for testing ond odiusting the shock
obsorbers ore given
in the following Tobles.
Front Shock Absorber -
see Fig.8.3/1
type PT 26x110,
Ser. No.443.621-215.000
1977-74 1 978 on
Maximum stroks llO mm 110 mm
Damping torce during
down stroke (compr€s-
sion 470N
500N
Damping force
during
upward stroke (expan-
sion) loSN
1
300N
Filling capacity lOO cc1OO
cc
Reor Shock Absorber
type T 26x175; Ser. No. 443.621.247.OO1
1977-78 1 978 on Both
types of shock obsorbers ore of similor
design, only their bottom fostening
is different
(the front shock obsorber hos o fostening eye,
the reor shock obsorber hos
o bolt ond locks
the outer protective
tube). They hove
o differ-
ent stroke, domping force, ond filling
copocity.
Removing ond Refitting When removing or refitting o shock
obsorber,
retoin the piston
rod (upper
fostening) by hold-
ing the flottened end of the threod in o sponner.
In the cose of
the reor shock cbsorber, retoin
the piston
rod in the bottom port
by holding the
heod of the bolt connecting it to the shock
obsorber cylinder.
The ossembly of the rubber bushes of the
respective shock obsorber mounting
con be seen
in Fig.8.3/1.
Access to the upper mountings of 'the
front
shock obsorbers is from the luggoge boot
(under the floor). The
threod is protected
by
o cop nut. The
mountings of
the reor shock
obsorbers ore occessible from the reor luggoge
comportment behing the reor seot bockrests ofter folding owoy the upholstery on the wheel
orch. The mounting is in the cyllndricol exten-
sion piece
in the scuttle
of the reor dosh.
Shock Absorbor Dismcntling
Dismontling is o routine procedure
beginning
with screwing out the plug
(1)
ofter the pro-
tective sleeve (tube)
hos been removed. Never
dismontle the piston
volves since there is o risk
of impoiring the domping force
by mixlng up
the volves.
o
o
*)
At o
temperoture ol 25
to 30oC,
of 100 strokes per
minute, ond
100 mm. frequency
stroke of
Fig.8.3/1 -
Front Shock Absorber -
Sectionol View
Maximum stroke
175 mm
175 mm
Damping force during
down stroke (compres-
ston, 470N
500N
Damping force during
upward stroke {expan-
sronl 950N
r
200N
Filling capacity 160
cc 160 cc
130

sallol
dod
;o Jequnu ocnper
'Apoq errlon Jo ellDn r*eueu reL
Apoq en;on uollcns uo
aco; 6u;1oes e6rol oo1 'en1on
uollcns lo e^lD^
lslp PoiIcnS uolssa:dtuoc uo
ec.ro; Oulduop e^lssecxl
dn),ls!J
leAl
-olc
6ur
.uei
leel
slsi
a6o
rc0
lq
loo
luo
ua€
aqt
{co eqt
u!D:
.JEU
-plc 'rgc
'Art
'Jel src'eA(
1Ue, JDII
Jaqrosqo
)coqs a-lllue
qsnll 'rallDr-u
u6ta:otr elotuaU a^lDA
uollcns
lo se^lD^
dod uaervrlaq JellDu.r u61arc1 uolssalduoc
tttt
aoro; 6trtdurop alonbapoul
se^lDA dod 1o
qlDuerls Jo Jeqtunu esDeJcul
seuo rttau qllM
suDd
uronn aco;deJ 'ocuDrDelc
lcaqC
ap;nD Meuau
aAIDA Meuau
reqJosqD lsoqs
qsnll 'JeUDu
u6ga:o1 e^oulau se^lDA
dod 1o roqunu alonbepou;
sl!ru!l ecuDJelol lgqo.replsuoc
speacxe :epu;;lc 6u1>;ror*
puo uolsrd ueeMloq ocuDloelC
IsDls eplne
pel.rolsrp uo1s1d eloqD a^lDn
palDes
A;1ce.r.roc lou uolsld
e^oqD e^lD^
oslp -
llo u! Jeuor-u
u61e"ro3 (uolsuodxe)
punoqel
uo
ac.ro; 6uldtuop alonbepoul
ApeuaX asnDc
lcelacl
loeg q1u1.rlqD'l ro1
c{t{ Yo rloqS loltd
-
Zlt'g'6t)
'doqs .r;oder pez!lD!ceds o u1 pe.rlode.r
roqiosqD
lcoqs oql
a^Dq 'leqlosqo
{cot{s eql
u!
llo }o
IcDl D iq
pasnoc
lou elo
qclqm 'eclo;
Duldutop
lo ssol egduoxe
lo; ':noco
slcoleP Jeqlo ll
'(A:ossecau sD 'dn
do1 puo
lessa^ palonpo:O D olu! JeqrosqD
)coqs
eql uol,
llo eql:nod)
lunouD pepuauulocel
oqtr
ol l!o dn dol '6u11cod
oql ro
;oes qlul.tAqol
aqt
6u;co1de: ol!qg 'JeqrosqD
lcoqs eql
lo ocDl.rrrs
aql uo s.roaddo ;1o .raduop 'esDc
D qcns
u1 '6n1d
eqt ,o 6urlcod
peBourop eql
ro pol
uolsgd eql
lo loes qlul.rAqog paBor.uop
eql ol anp a6o1oe1
ieqlosqD lcor{s sr
}ce}ep luanber; }sou eql
srgodeg -
slcaleq reqrosqy
lcoqS
'saqsnq reqqnl Puo salo;d 'a';
'"-1.rod 6urue1so1 anllcedsal aql
PUD leqJosqD lcoLls
luor] aql
lo (eqnl)
eleels anllcalord
eLll uo 6ugdd;1s Aq ilqtuessDer eql e1e;dtuo3
'lr uelq6!t puo
6n1d aql
llt ';1o
raduop qllm
enoolb ep1n6 eql u! 6u;.r 6u;1oes eql
IDoS 't
'a1o1d 6uguolel 6u;.rds aql olut
tloqs 1o1rd eq1
6uo1o sprDMurltop 6u1co; (,,11o
ol ep!s s!qL,) ,,!!elo ) DuDrlS,,
uog1dl.rcsu1
eq1
qpM loas qtu;.rAqo;
perode.rd
aqt d!gs puD por
uolsgd eql uo (ZttA '613)
1;oqs 1o;1d aq1
llDlsul
'toes q1u1rlqol aLll olu!
(asoa.r6
V)A1O6 )
eplqdlnslp unuapqA;otu
1o (1q61eaa)
%Ol lnoqD
lo elnlxlulpD
uD qtlM
esoar6 Jolotx ecJoJ 't
'(ll)
e1o1d 6ugulDlar aql qltM (01)
6ug.rds eql
atDcol
puo 'euoq
1g ssa.rd 'epgn6
aql lo erroo.r6 eql
ol ul (e
) 6u;.r 6u;1oas
eql
llJ '.repugllc
6u;>1.rotnt'
aql olu!
Atfqbtl auoq
ll do1
puo' po.t
uolstd
eql ol uo (6)
eprn6 eql dtlg '.rapu;;lc
6u11totrt
arll otu! sa^lo^ puD (S)
uo1s1d perll
aql ql!M
(Z) po.r uo1s1d aq1 {1gn;atDc
uasu! MoN 'z
'l!o lo lunouo
tcoxa pepuouurocor
aql quM
l! ll!J '(F)
lerroq
rapullAc ralno eql olu! (g)
eAIDA uo!lcns pellrl
oLll tll!M (9)
tapulllc 6u11.rornt aql
llDlsul '!
'1ua5o 6u1uoa;c reqlouD ,ro
;ol1ed u!
ueql
111rvrg 's1.rod
lueuodtuoc rauu!
llD lo sseuuoalc
eLll ol uo!luellD ;otcads Iod 'I;quassDeJ
D uO
,t;qurassoeg Fqrosqv
{cotlS

Defect
Remedy
Jerky upword stroke Airlock
obove plston
Oil leokoge due to domoged
piston rod
Plug worked loose -
oil leoks
post the threod
Suction volve does not closc,
oil is forced Into reserve
tube -
oir is sucked
in obove
the plston Flll
shock obsorber
correctly
wlth oil
Renew piston
rod ond lobyrinth
seol -
check shock
obsorber
mountlng on cor
Reflll oil ond tighten plug
correctly
Remove foreign motter
from
suction volve -
renew suction
volve body lf volve seot
is domoged
Domping force increoses
on compression Excessive
oil filling Adiust to specificotio.ns
Shock obsorber knocks when
exponslon storts. Domping
force poor
ot first. loter rises
to normol Volve obove
piston
sticking Remove couse of
stlcklng, or
chlps -
renew volve, reflll shock
obsorber with oll
Check shock obsorbers for correct operotlon direct in position
in the cor uslng o diognostic
oppor'
otus or, ofter removol, on o
test bench in
complonce with molntenonce
instructlons.
132

8et
0rr WL
selorS
lo 6ulpealS
puo
PlnlJ alDrS
6'6
e{or8 PuoH 8'6
0rt sesoH
puD
6uld!d 'luDl
plnlJ elorg
L'6
relsooS alor€ 9'6
8tr
6tI
8tt repu!l^c
leeq^ alorS
luorJ 9'6
rapulllc lseqM elor€
roeu
r€
repuillc relsoht
e'6
irqureasv alorg luog z 6
Alqruessy elor€ rDeU
L'6
uo;1dglcse6 loc!uqcal
Ltr
9tl 9tt
99l
a6o6
wSls^s l)
vug -
6 t{l