Koni Tech - PDF - Koni North America
Koni Tech - PDF - Koni North America
Koni Tech - PDF - Koni North America
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KONI PRODUCTS<br />
ARRAY OF KONI STREET<br />
SHOCK ABSORBERS<br />
KONI offers a wide range of adjustable<br />
performance shocks and struts using<br />
the highest quality materials and<br />
designs to give your street car or truck<br />
optimized handling, ride, and control.<br />
Whether using a mono-tube or twin<br />
tube design, hydraulic or gas charged,<br />
internal or external adjustments, single<br />
or double adjustable, ride height<br />
adjustable or fixed, KONI brings out<br />
the best in every car.<br />
ARRAY OF KONI RACING<br />
SHOCK ABSORBERS<br />
For over 50 years, KONI has been<br />
the world leader in adjustable racing<br />
shock technology. From the world’s<br />
greatest circuits of Formula 1 and<br />
sports car racing to the weekend<br />
warriors on the local bullring tracks,<br />
KONI single, double, and quadruple<br />
adjustable dampers lead the way<br />
with performance, control, and<br />
consistency.<br />
SUSPENSION KITS<br />
A. The KONI RSK kit includes four<br />
specially matched performance<br />
dampers and four lowering springs to<br />
provide improved ride and handling<br />
at a great price while offering tuning<br />
adjustments for height and damping.<br />
A. B.<br />
B. The KONI Threaded Suspension kits<br />
have four special externally adjustable,<br />
coil-over (where applicable) dampers<br />
and four lowering springs to give a<br />
large range of lowering and damping<br />
adjustability to improve handling and<br />
ride on the street.
TABLE OF<br />
CONTENTS<br />
KONI Products.....................................................................................................Inside Front Cover<br />
KONI <strong>Tech</strong> Line Frequently Asked Questions..............................................................................2-3<br />
Choosing the Optimum Damper/KONI Special vs. KONI Sport .....................................................4<br />
Why KONI?, KONI Philosophy ..................................................................................................5<br />
Adjustment Section<br />
Adjustment Procedures................................................................................................................6-9<br />
Strut Insert Installation Instructions...............................................................................................10<br />
Shop Services................................................................................................................................11<br />
Warranty<br />
Warranty Inspection Guide & Disposal Instructions......................................................................12<br />
Limited Warranty ..................................................................................................Inside Back Cover<br />
For Applications<br />
Use KONI Catalog 103609<br />
For Drag Racing and Road Racing Applications<br />
Use KONI Catalog 103610<br />
For Oval Track Applications<br />
Use KONI Catalog 103223<br />
SPECIAL ORDER SHOCKS<br />
Certain dampers are listed as special order in the application guide.<br />
In most instances these dampers are available within 60 days,<br />
or two weeks if you request to pay air freight charges;<br />
however in some cases there are minimum order quantities.<br />
To determine availability please call 859-586-4100.<br />
Identifying KONI Part Numbers. Refer to the chart below to determine an at-a-glance overview of the KONI part number prefixes<br />
and what feature each one indicates.<br />
CONSTRUCTION TYPE<br />
Twin Tube Low Pressure Gas<br />
Twin Tube Hydraulic<br />
Mono-Tube High Pressure Gas<br />
ADJUSTMENT FEATURE<br />
Externally Adjustable<br />
Standard Adjustable<br />
Double Adjustable<br />
BODY STYLE<br />
McPherson Strut Cartridge<br />
McPherson Strut Complete Housing<br />
Standard Shock Absorber<br />
25 26 30 80 82 86 87 88 90 2812 3012 3013 8010 8040 8041 8042 8210 8212 8216 8240 8241 8242 8610 8640 8641 8740 8741 8742<br />
X X X X X X<br />
X X X<br />
X X<br />
-<br />
- X X X X X X X X<br />
X X X<br />
X X X<br />
X<br />
X X X<br />
X<br />
X<br />
X X X X X<br />
X X X X X X X X X X<br />
X<br />
X X<br />
X X<br />
X X<br />
X<br />
X<br />
X<br />
X X X<br />
X<br />
X X X<br />
X X X X X X X X X X X X X X X X X X X X<br />
1
KONI TECH LINE FAQs<br />
(Frequently Asked Questions)<br />
Typically, having all the correct information makes all the<br />
difference when it comes to a choice of shock absorbers. Common<br />
questions asked of the KONI <strong>Tech</strong> Line are as follows:<br />
Q: What is the difference between KONI Special (red)<br />
and KONI Sport (yellow)?<br />
A: The KONI Special (red) has been engineered to maximize<br />
the ride comfort with good handling performance for each<br />
vehicle application. The KONI Sport (yellow) typically<br />
starts at a higher initial valving baseline to give a sportier<br />
feel and work on vehicles with higher performance parts.<br />
In some instances, KONI will only offer a Special or Sport<br />
valving and not both. Some modern cars come from the<br />
factory with higher tech suspension systems and<br />
wheel/tire packages so they would move directly into the<br />
Sport range, however they are still valved to give a<br />
comfortable ride with very good handling capabilities.<br />
Q: How much stiffer are KONIs than factory shocks?<br />
A: This is a difficult question to answer because every KONI<br />
application is developed for that specific vehicle to get<br />
the best ride and handling characteristics. In general,<br />
most factory shocks are under damped for optimized<br />
handling so KONI engineers select firmer valvings.<br />
Unfortunately factory shocks are generally chosen for<br />
financial reasons rather than performance so lower<br />
technology, cheaper shocks are the standard. In some<br />
instances, a factory shock may have good characteristics<br />
in some parts of the working range but need some help in<br />
other parts and there are even a few instances where the<br />
KONI engineers found better handling by softening the<br />
factory units.<br />
Q: What is the best adjustment setting for my shocks?<br />
A: There is no single best adjustment setting for your KONIs<br />
because every driver and vehicle has different<br />
preferences for comfort, performance, performance<br />
modifications and roads to drive on. For most vehicles,<br />
we suggest that new KONIs be installed in the full soft<br />
position (the standard setting right out of the box) to take<br />
advantage of the balance of ride comfort and handling<br />
designed by the KONI ride development engineers. If the<br />
car has performance upgrades (springs, wheel/tire<br />
packages, etc.) or the driver wants the car a bit more<br />
aggressive, most people find the optimum setting in the<br />
1/2 to one full turn from full soft range. Over the extended<br />
life of the damper or if the driver wants a specific firm<br />
handling characteristic, the dampers can be adjusted up<br />
higher. Very rarely will a KONI ever need to be adjusted to<br />
the full firm setting.<br />
Q: What are the best springs to match with my KONIs?<br />
A: One of the great advantages of KONI adjustable shocks is<br />
that there is no specific spring for matching optimum<br />
performance. Instead you can adjust your KONIs to match<br />
your springs. Most performance springs have a higher<br />
spring rate than the vehicle's original springs. Since the<br />
shock controls the motion of the spring, increased spring<br />
rates require more rebound damping for control and that<br />
is one of the reasons why KONIs are rebound adjustable<br />
(and some are double adjustable). Using higher rate<br />
springs with OE or soft shocks will very quickly overcome<br />
and wear out the shocks. The KONI adjustment range is<br />
typically about 100% (twice as firm at the full firm setting<br />
as at the full soft setting) to allow for the proper damping<br />
of OE springs and high rate performance springs.<br />
Q: How far can I safely lower my car?<br />
A: KONIs are designed to fit standard height cars and can<br />
work with lowered cars as long as they don't bottom out<br />
internally and become damaged. Unlike some shocks,<br />
KONIs are not position sensitive so they will work<br />
properly anywhere in their stroke range providing they<br />
are not bottoming or topping out. Different vehicle<br />
suspension designs have different stroke travels but a<br />
good rule of thumb is that most vehicles can be lowered<br />
acceptably about 1 1/2 inches, beyond that the possibility<br />
of bottoming increases rapidly although some longer<br />
stroke cars can go lower. Most vehicles are equipped with<br />
bump stops to keep the shocks and springs from<br />
bottoming out. When lowering a vehicle be sure to reuse<br />
your bump stops because they are cheap insurance to<br />
avoid bottoming damage. Remember also that severely<br />
lowered vehicles typically have negative effects on<br />
suspension geometry, ride quality and handling, and tire<br />
and suspension part wear.<br />
Q: KONI makes some shocks that are not gas shocks.<br />
Why?<br />
A: There are basically three types of shock absorber<br />
designs: mono-tube high pressure gas, twin-tube low<br />
pressure gas, and twin-tube hydraulic (non-gas). Each of<br />
these designs has certain ride and performance<br />
characteristics that can enhance the performance of a<br />
vehicle and KONI is the only company that makes all<br />
three designs. KONI ride development engineers evaluate<br />
each new vehicle and can decide which shock design<br />
would best apply to that vehicle. Some cars respond best<br />
to mono-tubes, some like gas pressurized and others<br />
don't. Most shock companies utilize only one or two<br />
of these styles because it is less expensive for<br />
manufacturing but are therefore, limited in design<br />
capability and function.<br />
Q: How do I adjust my KONI dampers?<br />
A: In order to determine the adjustment method for you must<br />
first determine the damper series. The series is the first 2<br />
or 4 digits before the space in the part number. Based on<br />
this number refer to the adjustment section of the KONI<br />
<strong>Tech</strong>nical Manual or on the web site www.koni-na.com.<br />
2
KONI TECH LINE FAQs<br />
(Frequently Asked Questions)<br />
Q: I want to lower my car with a coil-over sleeve kit.<br />
How do I setup my vehicle with KONIs and coilover<br />
sleeves?<br />
A: There are many coil-over sleeve systems on the market<br />
but the key is to get ones that will fit the KONI damper<br />
properly. Most of these are built to fit over a large<br />
number of aftermarket shock absorber brands but this<br />
means many will not really fit well. KONI is unique in<br />
that some applications feature an adjustable spring<br />
seat mounted on a circlip on the shock body. This<br />
circlip design is extremely strong when it is loaded<br />
properly and the circlip is captured so that it cannot be<br />
forced open. However if the mounting on the circlip is<br />
unevenly loaded or not properly captured allowing the<br />
circlip to increase in diameter from load or impact, you<br />
have a potentially dangerous situation where damage<br />
could occur. With proper installation and loading, the<br />
circlip system allows for great strength and ride height<br />
adjustability at the same time. Additionally, when<br />
selecting and installing your coil-over system, care<br />
should be taken to avoid allowing the springs to coil<br />
bind (compressing the spring down to a solid state)<br />
during usage as this can risk bottoming and damage. A<br />
proper length bump rubber should be used to keep the<br />
spring from coil binding and the shocks from bottoming<br />
internally. You should contact the dealer or the<br />
manufacture of the coil-over system and get any<br />
necessary adapter rings necessary to mount the sleeve<br />
system to the KONI.<br />
Q: Why are some KONI shocks not externally adjustable?<br />
A: Whenever possible, we try to have the application be<br />
externally adjustable so that they can be easily<br />
adjusted on the car. In some cases this is not possible<br />
due to design constraints imposed by the vehicle. Some<br />
cars have no way to physically access an adjuster on<br />
the car or have mounts that prohibit an adjustable<br />
shock. In these cases, the shocks are still adjustable<br />
but must be removed from the car to do so.<br />
Q: What’s the difference between the standard KONI<br />
shocks and those in the Threaded Suspension<br />
Kits and the RSK kits?<br />
A: The dampers in Threaded Suspension Kits are based on<br />
KONI Sport shocks but have been made specifically for<br />
the elements of the kits. Depending on the applications,<br />
some have different maximum or minimum lengths and<br />
valvings to specifically match the springs and lowering<br />
goals of the kits. Most are plated and threaded bodies<br />
and some are tight steel sleeves on yellow painted<br />
shock bodies.<br />
The dampers in the RSK kits are based on the red<br />
painted KONI Special shocks but they have been<br />
specifically valved to work with the kit springs.<br />
Additionally they have multiple spring perch grooves in<br />
them so the height of the car can be adjusted at the<br />
time of installation.<br />
Q: What is the KONI warranty? How do I go about<br />
getting replacements?<br />
A: The KONI warranty is a lifetime warranty to the original<br />
purchaser against defects in materials and workmanship<br />
and against wear out for as long as you own that car<br />
registered for street use. The warranty does not cover<br />
damage to the parts caused by misuse, misapplication,<br />
installation, motorsports, etc. If you determine you have a<br />
defective damper you can either contact the company<br />
which you purchased the unit(s) from or contact KONI<br />
<strong>North</strong> <strong>America</strong> directly at warranty@koni-na.com or<br />
859-586-4100. To process your warranty, we will require a<br />
copy of the purchase receipt and a vehicle registration.<br />
We will generate a return goods authorization (RGA) and<br />
can replace the dampers in advance at your discretion.<br />
For more specific information about the warranty see<br />
inside back cover.<br />
Q: I own a vehicle with sealed struts, yet you offer an<br />
insert for it. How is this possible?<br />
A: KONI has designed an ingenious method of installing<br />
inserts into sealed housings thus allowing the use of<br />
performance dampers when they were previously<br />
unavailable. It has become common practice for auto<br />
manufacturers all over the world to save money by using<br />
factory sealed strut housings rather than the traditional<br />
threaded closed housings when they build new cars.<br />
Whenever possible, KONI will make a complete strut<br />
housing damper but sometimes the necessary spring<br />
perches and mounting brackets are unavailable or<br />
financially unfeasible to produce. By designing the KONI<br />
Cut-A-Strut insert system, now many vehicles with<br />
factory sealed struts have performance damper options.<br />
The installation requires only basic tools which most<br />
individuals already own. These tools include a cutting<br />
device such as a hacksaw, grinder or pipe cutter to open<br />
the strut housing as well as an electric drill. Generally it<br />
takes an average of 15-20 minutes additional labor per<br />
corner over a traditional strut insert installation. KONI has<br />
been using this method very successfully for many years<br />
on numerous applications from Porsche to Ford, Honda<br />
to Hyundai. If you have any questions, please feel free to<br />
contact KONI, your dealer, or see instructions on-line at<br />
www.koni-na.com.<br />
Q: How can I get my business listed as a KONI<br />
Authorized dealer on the Distributor Search on the<br />
www.koni-na.com website?<br />
A: Contact your KONI wholesaler. They will determine what<br />
opportunities are available to you.<br />
KONI TECH LINE<br />
PHONE: 859-586-4100<br />
info@koni-na.com<br />
<strong>Tech</strong>nical Questions can be answered 8-5 EST M-F.<br />
3
DAMPER DESIGNS<br />
All Hydraulic shock absorbers work by the principle of<br />
converting kinetic energy (movement) into thermal energy<br />
(heat). For that purpose, fluid in the shock absorber is forced to<br />
flow through restricted outlets and valve systems, thus<br />
generating hydraulic resistance.<br />
A telescopic shock absorber (damper) can be compressed and<br />
extended; the so called bump stroke and rebound stroke.<br />
Telescopic shock absorbers can be subdivided into:<br />
1. Twin-tube dampers, available in hydraulic and gas-hydraulic<br />
configuration.<br />
2. Mono-tube dampers, also called high pressure gas shocks.<br />
TWIN-TUBE SHOCK ABSORBERS (fig. A and B)*<br />
The main components are:<br />
• outer tube, also called reservoir tube (6)*<br />
• inner tube, also called cylinder (5)*<br />
• piston (2)* connected to a piston rod (1)*<br />
• bottom valve, also called footvalve (7)*<br />
• piston rod guide (3)*<br />
CHOOSING THE OPTIMUM DAMPER FOR YOUR VEHICLE<br />
How Does a Twin-Tube Shock Absorber Work?<br />
Bump stroke.<br />
When the piston rod is pushed in, oil flows without resistance<br />
from below the piston through the outlets A*, B*, C*, and D* and the<br />
non-return valve (19)* to the area above the piston. Simultaneously,<br />
a quantity of oil is displaced by the volume of the rod entering the<br />
cylinder. This volume of oil is forced to flow through the bottom<br />
valve into the reservoir tube filled with air (1 bar) or nitrogen gas<br />
(4-8 bar). The resistance, encountered by the oil on passing<br />
through the footvalve, generates the bump damping.<br />
Rebound stroke.<br />
When the piston rod is pulled out, the oil above the piston is<br />
pressurized and forced to flow through the piston. The<br />
resistance, encountered by the oil on passing through the piston,<br />
COMPARING KONI SPECIAL vs KONI SPORT<br />
The characteristics of shock absorbers hardly ever get the<br />
attention they deserve, despite the damper being responsible for<br />
comfort, roadholding, stability and safety.<br />
Below is a force velocity graph of a KONI SPECIAL and a KONI<br />
SPORT shock, both designed for the same vehicle. The graph<br />
displays the adjustment ranges for both shocks. The pink area<br />
generates the rebound damping. Simultaneously, some oil flows<br />
back, without resistance, from the reservoir tube (6)* through the<br />
footvalve to the lower part of the cylinder to compensate for the<br />
volume of the piston rod emerging from the cylinder.<br />
MONO-TUBE SHOCK ABSORBER (fig. C)*<br />
The main components are:<br />
• (pressure) cylinder, also called housing<br />
• piston (2)* connected to a piston rod (1)*<br />
• floating piston, also called separating piston (15)*<br />
• piston guide (3)*<br />
How Does a Mono-Tube Shock Absorber Work?<br />
Bump stroke.<br />
Unlike the twin-tube damper, the mono-tube shock has no<br />
reservoir tube. There is still a need to store the oil that is<br />
displaced by the rod when entering the cylinder. This is achieved<br />
by making the oil capacity of the cylinder adaptable. Therefore<br />
the cylinder is not completely filled with oil; the lower part<br />
contains (nitrogen) gas under 20–30 bar. Gas and oil are<br />
separated by the floating piston (15)*.<br />
When the piston rod is pushed in, the floating piston is also<br />
forced down by the displacement of the piston rod, thus slightly<br />
increasing pressure in both gas and oil section. Also, the oil<br />
below the piston is forced to flow through the piston. The<br />
resistance encountered in this manner generates the bump<br />
damping.<br />
Rebound stroke.<br />
When the piston rod is pulled out, the oil between piston and<br />
guide is forced to flow through the piston. The resistance<br />
encountered in this manner generates the rebound damping. At<br />
the same time, part of the piston rod will emerge from th cylinder<br />
and the free (floating) piston will move upwards.<br />
shows the adjustment range where both shocks are equal in<br />
value. The red area indicates that portion unique to the KONI<br />
Special, while the yellow area is specific to the Sport shock only.<br />
When a car accelerates, brakes or rolls, typical damper speeds<br />
are in the (A) area. Damper speeds caused by road surface<br />
irregularities (bumps, railroad tracks, etc.) are in the (B) area.<br />
KONI Special (red or black). The KONI Special dampers are<br />
designed to offer the best compromise between road handling<br />
and comfort. If only a Special damper is listed, its adjustment<br />
forces are designed for all driving requirements.<br />
KONI Sport (yellow). The KONI Sport dampers are designed<br />
for aggressive driving or cars with suspension upgrades while<br />
continuing to offer comfort. If a KONI Sport is listed as an<br />
alternative to the KONI Special, choose Sport for aggressive<br />
handling characteristics.<br />
KONI Sport (yellow) shocks are identified by the Sport suffix<br />
(example, 8040-1026 Sport). KONI Special (red or black)<br />
shocks are listed without the Sport suffix (example, 8040-1026).<br />
4<br />
*PLEASE REFER TO DIAGRAMS ON PAGE 5
QUALITY<br />
WHY KONI?<br />
A KONI is not your average shock absorber.<br />
They feature a number of standards that make<br />
them unique:<br />
ADJUSTABLE: to set them to your personal<br />
preference and to compensate for wear.<br />
TAILORMADE: not a copy of the original,<br />
but designed for a specific car or even<br />
conditions.<br />
IMPROVEMENT: individually tested until<br />
the optimum in handling and comfort is<br />
reached.<br />
SAFETY: the handling of your car is a<br />
major issue for your own safety.<br />
INVOLVEMENT: KONI test drivers are<br />
dedicated car enthusiasts themselves.<br />
BUILT FOR A LIFETIME: a set of KONI<br />
shock absorbers will usually outlive your car.<br />
KONI PHILOSOPHY<br />
As KONI is known as the shock absorber specialist par excellence, we<br />
commit ourselves to delivering to our customers the finest quality product<br />
with the best performance. KONI has vast experience, and a world-wide<br />
reputation in developing their products for all applications.<br />
Our engineers ensure that every product is manufactured to meet the<br />
highest standards. KONI shock absorbers are produced from the finest<br />
materials; surfaces are machined to the narrowest tolerances and quality<br />
control is incorporated in all production steps. At the end of the production<br />
line every single damper is 100% dyno-tested to assure highest quality.<br />
This philosophy results in unrivaled lifetime, superb road performance and<br />
maximum customer satisfaction. Our philosophy is one of no compromises!<br />
A B C<br />
KONI TECHNOLOGY<br />
KONI experts recognize that every vehicle has<br />
unique damping needs. KONI manufactures<br />
three shock absorber technologies in order<br />
to choose the perfect damping solution.<br />
Every KONI is adjustable for ultimate performance<br />
benefits.<br />
KONI Shock Absorber Components:<br />
1 Piston rod<br />
2 Piston<br />
3 Piston rod guide<br />
4 Piston rod seal<br />
5 Inner Cylinder<br />
6 Reservoir tube<br />
7 Foot valve<br />
8 Bypass valve<br />
9 Bypass spring<br />
10 Adjusting nut<br />
11 Adjusting knob<br />
12 Adjusting detent<br />
13 Compression valve assembly<br />
14 Rebound valve assembly<br />
15 Floating piston<br />
16 Dust cover<br />
17 Adjusting rod<br />
18 Dust cap<br />
19 Non return valve<br />
20 Non return valve<br />
21 Valves<br />
A, B, C, D, E, F, G, H, J, K and L<br />
Various orifices<br />
TWIN TUBE TWIN TUBE MONO-TUBE<br />
HYDRAULIC LOW PRESSURE GAS HIGH PRESSURE GAS<br />
5
ADJUSTMENT<br />
PROCEDURES<br />
26, 30 SERIES<br />
REBOUND ADJUSTMENT PROCEDURES<br />
The adjustment is made with the shock fully extended.<br />
1 Remove the plastic dust cover to expose the adjusting button<br />
(Figure 2).<br />
2 Hold the damper body by hand where the piston rod emerges<br />
from the cylinder. Push the button carefully, by hand, and hold<br />
it in that position (Figure 1 & 2). (Do not use any device, other<br />
than by hand, to depress button).<br />
3 The adjusting device has been provided with a number of<br />
clearly distinguishable stops (clicks), each of which marks an<br />
adjustment position (zero + 3 clicks = 4 positions) (Figure 4).<br />
4 The damper may have already been adjusted earlier.<br />
Therefore, check whether the shock absorber is in the zero<br />
position by turning the piston rod to the left (counterclockwise)<br />
with the other hand until the zero-stop is felt - DO NOT USE<br />
FORCE!<br />
5 To increase rebound, turn the piston rod one or more clicks to<br />
the right (clockwise), and release the adjusting button.<br />
6 Be sure that the adjusting button fully springs back into<br />
position. As long as the button is depressed, do not turn the<br />
piston rod further; otherwise correct adjustment will be<br />
disturbed. As soon as the button has made its complete<br />
return, the piston rod may be turned freely. The damper can<br />
now be refitted.<br />
Figure 3. Do not place the shock absorber in a vise<br />
(except at the lower eye). See Figure 2.<br />
Figure 1.<br />
Figure 1. UNIQUE. The handy adjustment<br />
button. Depress the button while turning<br />
clockwise to give increased damping forces.<br />
Figure 4. Rebound Adjustment (approximate forces). Listen for the clearly<br />
distinguishable clicks, each of which marks an adjustment position. 26 Series<br />
range limited to two clicks. 28 and 30 Series range is three clicks.<br />
ADJUSTING DIRECTION<br />
Clockwise = Firmer<br />
Counter Clockwise - Softer<br />
6
ADJUSTMENT<br />
PROCEDURES<br />
80, 82, 86, 87, 88, 90, 8040, 8240, 8640 SERIES<br />
REBOUND ADJUSTMENT PROCEDURES<br />
Remove the shock absorber from the vehicle and hold it<br />
vertically with the lower eye or pin attachment in a vise. Use<br />
clamp plates to prevent damage.<br />
Fully collapse the shock absorber, at the same time turning the<br />
dust cap or piston rod slowly to the left (counterclockwise),<br />
until it is felt that the cams of the adjusting nut engage in the<br />
recesses of the foot valve assembly.<br />
Some shock absorbers include a bump rubber concealed under<br />
the dust cover that must be removed prior to adjusting.<br />
The damper may have already been adjusted. Therefore check<br />
whether the shock absorber is in the unadjusted position or not<br />
by keeping it collapsed and gently turning further to the left<br />
counting at the same time the half turns until a stop is felt. Stop<br />
turning then and do not use force.<br />
Keeping the shock absorber collapsed, make 1 half turn (180 o )<br />
to the right (clockwise). In case of prior adjustment add the<br />
number of half turns previously found. The total range is about<br />
5 half turns.<br />
Pull the shock absorber out vertically without turning for at least<br />
1 cm to disengage the adjusting mechanism. The dust cap or<br />
piston rod may now be turned freely.<br />
ADJUSTING DIRECTION<br />
Clockwise = Firmer<br />
Counter Clockwise - Softer<br />
7
ADJUSTMENT<br />
PROCEDURES<br />
8010, 8041, 8042‡, 8241, 8610, 8641, 8710, 8741, 8742‡ SERIES<br />
REBOUND ADJUSTMENT PROCEDURES<br />
Externally Adjustable. These dampers can be adjusted,<br />
literally at the turn of a knob, a technique borrowed from<br />
Formula-1 racing where KONI dampers have dominated the<br />
field for years. One can switch back and forth, in most cases in<br />
a matter of seconds, from a comfortable “touring” setting to a<br />
more firm setting for a sporty drive. By means of a knob the<br />
damping forces can be altered to driving conditions or personal<br />
preferences.<br />
‡Also adjustable in compression.<br />
REBOUND<br />
ADJUSTMENT DIRECTION<br />
Clockwise = Softer<br />
Counter Clockwise - Firmer<br />
COMPRESSION<br />
ADJUSTMENT DIRECTION<br />
Clockwise = Firmer<br />
Counter Clockwise - Softer<br />
8
ADJUSTMENT<br />
PROCEDURES<br />
8042‡, 8210†, 8211, 8212, 8216†, 8242‡, 8742‡ SERIES<br />
Independently adjustable in both compression and rebound,<br />
this series racing shock absorbers offer over 140 different<br />
combinations of compression and rebound, to finely tune the<br />
chassis for maximum performance.<br />
General Precaution - Do not place piston rod in a vise, nor<br />
cause damage to the rod surface. (Figure 3)<br />
Rebound - Insert a pin into the slotted adjuster located at top<br />
eye (Figure 1). Moving the pin from left to right (counterclockwise)<br />
will cause the forces to increase. From the<br />
minimum or factory position, there are 12 possible sweeps of<br />
adjustment (1 sweep equals 1/4 turn).<br />
Compression - Insert a screwdriver into the lower<br />
adjustment device (Figure 2). Turning the screw driver from<br />
left to right (clockwise) will cause the forces to increase. From<br />
the factory or minimum position, there are 12 possible “clicks”<br />
of adjustment.<br />
ADJUSTMENT DIRECTION<br />
ADJUSTMENT DIRECTION<br />
Figure 2. Turn screw from left to right to increase<br />
compression forces. (Clockwise)<br />
Figure 3. Do not place the shock absorber in a vise (except at<br />
the lower eye). See Figure 2.<br />
Figure 1. Move pin left to right to increase rebound forces<br />
(counter-clockwise).<br />
9
For normal use on the road, the new strut dampers must be fitted<br />
straight from the box. (Original adjustment). In all other cases see<br />
enclosed adjustment instructions.<br />
1. ATTENTION: In case of adjustable attachments mark off their<br />
position first before unscrewing the nuts to obtain<br />
correct adjustment of wheel camber and caster<br />
angles after fitting.<br />
Remove the complete suspension unit from the car. Compress the<br />
spring with coil spring clamps. Remove the fixing parts, bump rubber,<br />
dust cover (if any), spring, etc., keeping in mind the correct sequence<br />
and position for refitting.<br />
★ The parts (drawn in dotted lines) could be absent or of a different<br />
shape.<br />
2. Punch in the exact center of the base of the damper housing. First<br />
drill a pilot hole of 3 mm diameter and then drill to ø 14 mm<br />
(fig. a). Drain oil.<br />
3. Saw off (depth 1.5-2 mm) the original damper housing, as shown<br />
with dotted lines in fig. b for the several types I + II. The cut must<br />
made at highest point on the strut housing where the overall<br />
diameter is maintained. If the shock absorber interior cannot be<br />
removed by hand, use a light hammer. Remove all the inner parts.<br />
Beware of outstreaming oil.<br />
4. Smooth the drilled hole on both sides. File off the nail W and clean<br />
the inside of the damper housing (fig. c).<br />
5. Fit the rubber protection cover R on the strut damper (fig e-II) and<br />
slide the latter into the housing.<br />
6. Fit now plate X - if supplied- with its profiled side directed to the<br />
bottom, then the locking ring and the bolt (fig. d).<br />
7. Draw the strut damper deeper into the original housing by tightening<br />
the bolt with a torque of 85 Nm (63 ft.lbs) and fit the rubber<br />
protection cover as per fig. e-II.<br />
8. De-aerate the strut damper with piston rod by fully extending and<br />
compressing it several times.<br />
9. Keep the piston rod extended as much as possible and place<br />
plastic collar Y -if supplied- between the damper body and the<br />
bumprubber (fig. e).<br />
10. Fit the suspension unit in reverse order of dismantling. Renew the<br />
bump rubber, dust cover etc. in case of damage.<br />
11. Tighten the fixing nut Z home as far as stop (bush or pin collar)<br />
using the torque setting prescribed in the table. (fig. f) and<br />
release the spring.<br />
“CUT-A-STRUT” STRUT INSERT<br />
INSTALLATION INSTRUCTIONS<br />
FITTING OF "BOLT-THROUGH-THE-BOTTOM" STRUT DAMPERS<br />
ATTENTION:<br />
To avoid any unwanted adjustment of the strut damper<br />
never use a pneumatic or electric impact wrench.<br />
Check and set wheel alignment after fitting.<br />
10
SERVICE CENTER<br />
KONI SERVICE CENTER<br />
KONI operates a full service shock absorber service<br />
center to provide complete testing, fabrication,<br />
restoration, and revalve capabilities. The facility<br />
includes services for automotive, motorsports, heavy<br />
duty bus and truck, railway and industrial applications.<br />
DYNO TESTING – All KONI dampers are dynamometer<br />
tested when they are manufactured, however, racing<br />
dampers should be dyno tested periodically to ensure<br />
optimum performance. KONI offers dyno services<br />
utilizing the latest technology in computer operated<br />
multi- and single speed dynos.<br />
REBUILD – KONI dampers, in most cases, are fully<br />
rebuildable. Vintage street and racing shocks can be refurbished<br />
to like-new condition including paint and decals.<br />
REVALVE – In cases where the original KONI valving<br />
may not be optimal for modified vehicles, the valving<br />
may be altered to match upgraded suspension<br />
requirements. KONI has developed specific valvings<br />
for motorsports applications including autocross, drag<br />
racing, oval track racing and road course racing.<br />
SPECIAL APPLICATION CONVERSIONS – The KONI<br />
Service Center can perform a variety of special<br />
modifications including shortened and extended<br />
lengths, double and external adjustability and special<br />
mounting configurations. Contact the KONI Service<br />
Center with your special requirements.<br />
OTHER KONI AUTHORIZED REBUILD FACILITIES –<br />
In addition to the KONI Service Center, there are two<br />
KONI authorized rebuild facilities in <strong>North</strong> <strong>America</strong>. Both<br />
utilized KONI trained technicians and KONI parts. They<br />
are TrueChoice in Hilliard, OH (800-388-8783) and Pro<br />
Parts West in Canoga Park, CA (818-348-5385).<br />
MOBILE SERVICE FACILITIES – KONI operates<br />
mobile service units complete with dyno testing and<br />
rebuilding facilities for Research and Development and<br />
motorsports support.<br />
HOW TO DO BUSINESS WITH THE KONI<br />
SERVICE CENTER<br />
Call KONI at 859-586-4100, Service Center hours are 7:30 a.m.<br />
to 4:00 p.m. EST. Dampers should be sent to: KONI <strong>North</strong> <strong>America</strong>,<br />
Attn: Service Center, 1961 A International Way, Hebron, KY 41048.<br />
Please include a note with a description of the services required<br />
and your name, address and daytime telephone number.<br />
Turn-Around Time: Normal turn-around time is two to three<br />
weeks from date of receipt but it is sometimes subject to<br />
seasonality so please call KONI in advance to determine your<br />
projected availability date. If faster delivery time is required<br />
(example: 3 working days), there will be a 50% overtime surcharge.<br />
Terms: Without exception all shocks must be sent to KONI<br />
freight prepaid. Method of payment will be VISA or MasterCard.<br />
Costs: Contact KONI at 859-586-4100 for current prices on<br />
services.<br />
NON-REBUILDABLE KONI DAMPERS<br />
Although most KONI dampers are rebuildable and revalvable, certain KONI dampers<br />
due to their unique configuration are sealed for life. Shocks which are not readily<br />
rebuildable include series: 25, 26, 2615, 30, 76, 7610 and some 8640 and 8641.<br />
Construction<br />
Sealed<br />
Rebuildable<br />
25 26<br />
x x<br />
2615 2812 2816 2817 30 3011 3012 3058 76 80 82 86 87 88 90<br />
x<br />
x<br />
x<br />
x<br />
x<br />
x<br />
x<br />
x<br />
x<br />
x x x x x x<br />
Construction<br />
Sealed<br />
Rebuildable<br />
7610 8040 8041 8210 8211 8212 8216 8240 8241 8242 8610 8640 8641 8710 8740 8741 8742<br />
x<br />
x x x x x x x x x x<br />
x<br />
x<br />
x<br />
x x x x x<br />
11
WARRANTY INSPECTION GUIDE<br />
& DISPOSAL INSTRUCTIONS<br />
NON-WARRANTABLE CONDITIONS<br />
A Light coating of oil. Normal wear incurred in service life.<br />
Presence of slight film is intentional and designed to help<br />
lubricate the piston rod.<br />
B Bent rod/damaged shock body. Indicates improper installation,<br />
collision damage, modification or abuse.<br />
C Broken or damaged mounting components (not shown).<br />
Indicates improper installation or abuse.<br />
D Worn bushings and mounting rubbers (not shown). Not<br />
covered under warranty.<br />
E Burned unit (not shown). Indicates exposure to fire or<br />
salvaged unit.<br />
WARRANTABLE CONDITIONS<br />
F Unbroken piston rod separated from shock body.<br />
G Bubbling noise (26,28,30 Series only). Indicates oil and gas<br />
have mixed. Test by inverting shock, compressing and<br />
releasing.<br />
H Incorrect compressed length. Compress old shock fully and<br />
measure exposed piston length to that of a new KONI of the<br />
same part number. If difference is more than 3/8” then shock<br />
is defective.<br />
J Clicking noise. Test by inverting shock, compressing halfway,<br />
then quickly moving the rod up and down an inch. Pronounced<br />
end play and click sound indicate a defective shock.<br />
A B F G H J<br />
DISPOSAL INSTRUCTIONS<br />
Figure 1.<br />
Figure 2. Figure 3.<br />
These instructions apply to the red, black and yellow shock absorbers.<br />
Appropriate protective measures should be taken when removing oil and<br />
gas from discarded and defective shock absorbers.<br />
1 The shock absorber should be secured in horizontal position.<br />
2 The piston rod should be fully extended before drilling.<br />
3 Drill a hole of approx. 5 mm diameter at 3 cm from the bottom of the<br />
shock absorber.<br />
Caution: gas and oil will be expelled from the shock absorber.<br />
Appropriate measures should be taken to limit the loss of oil.<br />
4 Drill a second 5 mm hole at 6 cm from the top of the shock absorber to<br />
ensure that all the oil is drained.<br />
5 Move the piston rod in and out to force the oil out of the shock absorber<br />
until the oil flow stops.<br />
The environmental protection authorities will provide information<br />
about the disposal of the oil and other components.<br />
Environmental Protection. The hydraulic oil drained from the shock<br />
absorbers should be collected and disposed of in accordance with the<br />
legislation concerning waste oil and other wastes.<br />
12
LIMITED WARRANTY<br />
PASSENGER CAR, LIGHT TRUCK,<br />
MOTORHOME & MOTORCYCLE<br />
KONI Inc. warrants all new KONI shock absorbers to the<br />
original retail purchaser (purchased after 5/1/80) against<br />
defects in material and workmanship, excluding mounting<br />
rubbers, washers and bushings, when used under normal<br />
operating conditions for as long as such purchaser owns the<br />
vehicle on which the KONI shock absorbers were originally<br />
installed. This warranty does not apply to, and KONI makes no<br />
warranty for, shock absorbers that have been installed;<br />
• Improperly;<br />
• As original equipment on any vehicle except Ford<br />
Mustang SVO;<br />
• On any vehicle that has been modified for a use other than<br />
or in addition to its originally intended use;<br />
• For an application that is not specified in the KONI<br />
literature;<br />
• On any vehicle that has been used off-road, for racing or<br />
for any other driving competition.<br />
HEAVY DUTY TRUCK & BUS<br />
KONI Inc. warrants all new KONI shock absorbers to the<br />
original retail purchaser against defects in material and<br />
workmanship, excluding mounting rubbers, washers and<br />
bushings, when used under normal operating conditions for a<br />
period of 3 years or 300,000 miles, whichever occurs first,<br />
(purchased after July 1, 1990). This warranty does not apply<br />
to, and KONI makes no warranty for, shock absorbers that<br />
have been installed:<br />
• Improperly<br />
• As original equipment on any vehicle which was<br />
manufactured outside of the U.S.A.;<br />
• On any vehicle that has been modified for a use other than<br />
or in addition to its originally intended use;<br />
• For an application that is not specified in the KONI<br />
literature;<br />
• On any vehicle that has been used off-road, for racing or<br />
for any other driving competition.<br />
In the event of defect, malfunction or failure of the KONI shock<br />
absorbers to conform with this warranty, the original purchaser<br />
must complete the KONI warranty claim form and return it with<br />
the shock absorbers, a copy of the vehicle's current<br />
registration and the dated proof of purchase to the dealer from<br />
which the shock absorbers were purchased, or to any<br />
authorized KONI distributor, or the KONI Inc. Upon<br />
verification, warrantor or its servicing organization will repair or<br />
replace the shock absorbers at no cost to the original user.<br />
However, warrantor will not pay for the cost of the installation<br />
of the new or repaired shock absorbers, and the cost of<br />
postage and return shipping cost shall be prepaid by the<br />
original purchaser.<br />
This warranty gives you specific legal rights, and you may<br />
have other rights which vary from state to state.<br />
THIS WARRANTY IS LIMITED SOLELY TO THE ABOVE AND<br />
THIS WARRANTY AND ANY WARRANTIES IMPLIED BY<br />
STATE LAW WILL APPLY ONLY FOR THE TERM STATED<br />
ABOVE.<br />
THE WARRANTOR WILL NOT BE LIABLE FOR ANY LOSS,<br />
DAMAGE, INCIDENTAL OR CONSEQUENTIAL DAMAGES<br />
OF ANY KIND WHETHER BASED UPON WARRANTY,<br />
CONTRACT OR NEGLIGENCE AND ARISING IN<br />
CONNECTION WITH THE SALE USE OR REPAIR OF THE<br />
PRODUCT.<br />
SOME STATES DO NOT ALLOW LIMITATIONS ON HOW<br />
LONG AN IMPLIED WARRANTY LASTS, OR ALLOW THE<br />
EXCLUSION OR LIMITATION OF INCIDENTAL OR<br />
CONSEQUENTIAL DAMAGE SO THE ABOVE LIMITATIONS<br />
OR EXCLUSION MAY NOT APPLY TO YOU. UNLESS<br />
OTHERWISE CONTRARY TO STATE LAW GOVERNING<br />
THE PURCHASE, THE WARRANTOR'S LIABILITY SHALL<br />
NOT IN ANY CASE EXCEED THE CONTRACT PRICE FOR<br />
THE PRODUCT CLAIMED TO BE DEFECTIVE OR<br />
UNSUITABLE<br />
(THIS WARRANTY IS APPLICABLE IN THE U.S.A. AND<br />
CANADA ONLY.)<br />
WARRANTY RETURN PROCEDURE<br />
1 Contact dealer from which shock absorbers were<br />
purchased, OR contact KONI, 1961 International Way,<br />
Hebron, KY 41048, attention KONI Warranty,<br />
Phone: 859-586-4100, to obtain a Return Goods<br />
Authorization number.<br />
2 Provide dated proof of purchase.<br />
3 Provide copy of current vehicle registration form.<br />
4 Provide your name, address, day phone number, make,<br />
model & year of vehicle and description of defect.<br />
5 Return defective unit(s) - (freight prepaid) - with all<br />
mounting parts and items 2, 3 and 4.<br />
6 Upon determination of valid warranty KONI will repair or<br />
replace at its discretion.