King Off-Road Racing Shock Rebuild and Revalve Instructions

To order seals, shims, shock oil, and replacement parts

visit FilthyMotorsports.com/King or call 303-834-7895

Parts Needed For Shock Rebuild

1 x King Seal Kit
http://www.filthymotorsports.com/kingseals
Parts Needed for Shock Revalve
2 x Replacement Valving Shim Stacks
http://www.filthymotorsports.com/kingshims
Optional Parts
1x King Shock Oil
http://www.filthymotorsports.com/shockoil

Required and Recommended Tools

- Small Allen Wrench Set
- Spanner Wrench (2" x 3/16" Pin)
- Dentist Pick or Small Screwdriver
- Adjustable Crescent Wrench
- Clean Bucket or Container
- Paper Towels or Clean Shop Rag
- Locite Thread Locker
- Small Dead Blow Hammer (Optional)
- Small Pliers (Optional)
- Bench Vice (Optional)

Step 1: Clean The Shock

Clean the shock completely using paper towels or a
shop rag to remove any and all dust and dirt. Do not
bleed the nitrogen pressure from the shock just yet.
Step 2: Loosen Set Screw
With the shock shaft fully extended, use an allen
wrench to loosen the set screw in the lower wiper cap.
Make sure the allen wrench is a good fit so as not to
strip the screw. Unscrew it just a few turns.

Step 3: Loosen the Wiper Cap

Set the spanner wrench securely into the two indented
holes on the wiper cap and using a medium amount of
force turn the wiper cap counter-clockwise. A small
tap with a dead blow hammer usually does the trick.
Do not remove the wiper cap.
Note: Nothing in this rebuild process should require
more than a small to medium amount of force and
everything should come apart smoothly.
Step 4: Bleed the Nitrogen Pressure
Bleed the pressure from the reservoir or shock body
on an emulsion shock through the Schrader valve
using a small screwdriver or allen wrench.
Note: The pressure is kept inside the shock through
this step because it keeps the internal seal cap pressed
against the snap ring to keep it from spinning freely
while the wiper cap is loosened.

Step 5: Unscrew the Wiper Cap

Finish unscrewing the wiper cap and slide it up to the
end of the shock shaft.
Step 6: Lower the Seal Cap
Press down firmly on the internal seal cap to push it
down below the snap ring.
Tip: If you move the shaft up and down a few times
forcefully and then bleed the pressure in the reservoir
again it will create a vacuum and suck the seal cap
down on its own. This may take a few tries.

Step 7: Remove the Snap Ring

With a small screwdriver or dentist pick, carefully
remove the snap ring and set it aside.

Step 8: Remove the Shock Shaft

Carefully pull on the shock shaft to remove it from the
shock body.
Tip: If you plan to reuse the shock oil, be extra careful
because it is easy to lose a lot of oil in this step. It may
also be helpful to bleed the reservoir again to release
the vacuum pressure created by pulling out the shaft.
Step 9: Drain the Oil
Drain the oil from the shock into a clean container.
Bypass Shocks - Make sure the bypass valves are open
so the oil can drain from the bypass tubes.
Remote Reservoirs - Lift the reservoir up to drain the
oil from inside the reservoir and reservoir hose.
Piggyback Reservoirs - Lean the shock body such that
the oil can drain from the piggyback reservoir into the
shock cylinder. Then turn the shock over and let the oil
drain out.
Tip: At this stage it is a good idea to inspect the oil for
unusual debris or metal shavings and inspect the shock
shaft and cylinder walls for scratches and damage.

Step 10: Remove the Piston Retaining Nut

Secure the lower rod end (bearing side) of the shaft
assembly in a vice and protect it with a towel or
rubber pad, then remove the piston retaining nut.
Tip: Never clamp the shock shaft in a vice unless you
have the proper shock shaft clamps.
Note: The wear band on the piston is usually good for
the life of the shock and rarely needs replacing.

Step 11: Remove the Piston and Shims

Carefully remove the shock piston, shims, and spacers
and lay them out in order.
If you are revalving your shocks, then this is the time
to replace the existing shims with the new ones.
Remember that compression shims go on the bottom
and rebound shims go on the top, towards the nut.
If you are not replacing any seals, then the seal cap
and wiper cap should stay on the shock shaft.

Step 12: Replace Cap Seals (Optional)

If you are performing a shock rebuild, remove the seal
cap, spacer, and wiper cap from the shock shaft.
Remove the existing seals and o-ring carefully using a
small screwdriver and/or small pliers.
The new seals are a tight fit but will push in by hand
without needing much force. Take your time to make
sure they are fully seated correctly.
Step 13: Reassemble the Shock Shaft
Slide all of the shock shaft components back onto the
shock shaft in the reverse order in which they were
removed.
Apply a small drop of Loctite (thread locker) to the
shaft threads before tightening the piston retaining
nut snugly.
Set the shock shaft assembly aside for now.

Step 14: Remove Bypass Tube Valves (Optional)

Remove the bypass tube valves by unscrewing the
larger of the two nuts. These nuts may be a little tight
and may require some force so be careful not to
damage them.

Step 15: Replace Bypass Valve O-Rings (Optional)

Using small pliers, carefully remove the bypass valve
from inside the bypass tube.
Replace the o-rings and then reinstall the valve and
nut.
Tip: Make sure that the valves remain open to allow
air to bleed through them during the oil filling process
coming up soon.

Step 16: Reservoir Rebuild (Optional)

Press down on the cap(s) to expose the snap ring(s)
and remove using a small screwdriver, similar to steps
6 and 7, above.
Apply a small amount of pressure to the Schrader
valve to pop the caps and internal floating piston out
from the reservoir cylinder.
Replace the o-rings and then reassemble.

Step 17: Set the Reservoir IFP

Charge the reservoir with a small amount of pressure
to push the internal floating piston to the bottom of
the reservoir cylinder.
Then, release the pressure from the reservoir so that it
is empty.
Step 18: Fill the Shock Cylinder with Oil
While holding the shock cylinder upright, pour the
shock oil into the cylinder until it reaches a point about
one inch under the snap ring groove.
For emulsion (non-reservoir) shocks use these
volumes instead:
2.0 x 6” 195 cc 2.5 x 6” 400 cc
2.0 x 8” 250 cc 2.5 x 8” 510 cc
2.0 x 10” 320 cc 2.5 x 10” 640 cc
2.0 x 12” 400 cc 2.5 x 12” 800 cc
2.0 x 14” 450 cc 2.5 x 14” 900 cc
2.0 x 16” 500 cc 2.5 x 16” 1,000 cc

Step 19: Cap and Flip the Shock Cylinder

Using your hand or any clean flat block (a hockey puck
works well), cover the open end of the cylinder and
turn it upside down and back a few times to release
any trapped air bubbles.
Add shock oil as needed to bring the oil level back to
around one inch below the snap ring groove.

Step 20: Slowly Insert the Shock Shaft

Carefully place the shock shaft assembly into the shock
cylinder until the entire piston is submerged. Move the
shaft up and down slightly and let any remaining air
bubbles work their way out.

Step 21: Set the Seal Cap

Slide the seal cap down to the top of the cylinder and
settle it down onto the shock oil.
Push down on the seal cap with moderate force to
move it down to just below the snap ring groove. Try
and do this in one continuous push because this is how
oil is forced into the reservoir.
Insert the snap ring into the groove.
Note: It is normal to lose a little shock oil here.
 Step 22: Charge the Reservoir
Charge the reservoir with the desired about of
Nitrogen (about 150 PSI) and then check for leaks.
Note: Sometimes this pressure will push the main seal
out of the seal cap. If this happens, carefully push in
back into position.

Step 23: Screw on the Wiper Seal

Thread the wiper seal onto the now seated wiper cap
and tighten securely using the spanner wrench. A few
light taps with a dead blow hammer may help.
Tip: Do not over tighten the wiper cap!

Step 24: Tighten the Set Screw

Tighten the set screw to secure the wiper cap.
Wipe off any residual oil and cycle the shocks a few
times by hand, it should move freely although with
some resistance through the entire stroke.
If you hear a lot of gurgling, then there is air in the
cylinder and you will need to repeat steps 21-24.
Small amounts of air are ok as they will eventually
move their way through the reservoir and past the
internal floating piston.

To order seals, shims, shock oil, and replacement parts

visit FilthyMotorsports.com/King or call 303-834-7895

For help with shock valving and shim stacks go to:

www.ShockTuning.com

This latest version of this manual is available on-line at:

FilthyMotorsports.com/KingRebuild

(Version 1.1 - Last Revised 8/9/13)

 King Off-Road Racing Shock Replacement Parts List

1 - Top Cap 19 - Seal Cap 37 - Reservoir Cylinder 55 - Wiper Cap Bolts

2 - Top Cap O-Ring 20 - Shaft O-Ring 38 - Res. Piston Wear Band 56 - Remote Reservoir Hose
3 - Secondary Nuts 21 - Main Seal 39 - Reservoir Piston 57 - Remote Res. Oil End Cap
4 - Secondary Nut O-Ring 22 - Main Seal Retainer 40 - Remote Res. Air End Cap 58 - Reservoir End Cap O-Ring
5 - Shock Cylinder 23 - Seal Cap O-Ring 41 - Schrader Valve 59 - Schrader Valve Cap O-Ring
6 - Coil Adjustment Nut 24 - Shock Cylinder C-Clip 42 - Piggyback Mounting Bolts 60 - Schrader Valve Cap
7 - Coil Spring 25 - Wiper Cap O-Ring 43 - Piggyback Mounting Plate 61 - Piston Bleed Screw
8 - Coil Slider 26 - Wiper Cap 44 - Piggyback End Cap Bolts 62 - Seal Cap Bleed Screw
9 - Coil Plate 27 - Wiper Seal 45 - Spacer 63 - Bypass Valve
10 - Piston Retaining Nut 28 - Set Screw 46 - Bearing C-Clips 64 - Bypass Spring
11 - Piston Retaining Washer 29 - Shock Shaft 47 - Spherical Bearing 65 - Bypass Valve Stop
12 - Valve Shims 30 - Rod End 48 - Piggyback Sleeve O-Rings 66 - Bypass Valve Stop Set Screw
13 - Piston Wear Band 31 - Coil Adjustment Pinch Bolt 49 - Piston O-Ring 67 - Bypass Valve Stop O-Ring
14 - Piston 32 - Piggyback Mounting Sleeve 50 - Main Seal C-Clip 68 - Bypass Adjusting Nut O-Ring
15 - Base Washer 33 - Reservoir C-Clip 51 - Wiper Seal C-Clip 69 - Bypass Adjusting Nut
16 - Top Out Washer 34 - Piggyback Adaptor O-Ring 52 - Wiper Seal Retainer 70 - Bypass Adjusting Screw
17 - Shaft Spacer 35 - Piggyback Oil End Cap 53 - Wiper Seal 71 - Bypass Adjusting Jam Nut
18 - Shaft Guide / DU Bushing 36 - Reservoir O-Rings 54 - Wiper O-Ring 72 - King Shock Oil