Integra 310-402XX User's Manual
Contents
1. pe SES INTEGRA RACING SHO ky gt IM TE GR u SHOCIS e Er E E ul 5 Eas E ul am gt Series 310 401 XX and 310 402XX WW Special Precautions BE SURE TO READ AND FOLLOW ALL PRECAUTIONS LISTED BELOW PRIOR TO BEGINNING WORK ON YOUR SHOCKS Integra Shocks are nitrogen gas charged for proper operation Discharge the nitrogen gas in the unit prior to working on your shock Failure to do so could cause serious injury or death Keep hands clean and free of dirt dust or other loose debris that could become lodged in the tiny passages located in the damper Rebuilding of your dampers can be done at the track Be sure to perform any rebuilds in an enclosed Space where dirt and dust are at a minimum Clean any oil spills from the floor immediately to reduce the chance of a slip or fall Always use safety glasses to reduce the chances of serious eye injury Be cautious when working over the damper when the nitrogen gas has not been discharged Read complete manual prior to beginning any work in your shocks m K it Contents 310 30202 The following parts are supplied with your Integra shocks valving kit Valve disc storage case Misc valve discs Bleed discs Spare piston bands Spare rod seals Spare rod guide seals Spare end cap seals Spare floating piston seals Spare nitrogen fill valves2. Shock Vise part 310 30204 Alternately you can use a standard vise using body clamps part 310 30311 purchased separately Do not over tighten clamps Permanent deformation of the tube will occur if the clamps are over tightened A2 a e Be sure the rod is completely extended of the shock e Using the rod guide wrench provided loosen the rod guide and slowly remove the head assembly A3 e Place the head assembly you have just removed on a clean low lint paper towel A4 e Pour the oil into a measuring cup or similar graduated cylinder Use a paint strainer to ensure that any large foreign particles are removed from the oil A5 A3 A4 A5 Loosen the gt Place head Place oil into rod guide and assembly on a measuring slowly remove low lint paper cup the head assembly towel Valving The Head Assembly 1 Clamp the head assembly in the vice B7 2 Set up a clean low lint paper towel on the bench next to the vice B1 Clamp 3 Using a marker label the upper right hand corner of the paper towel the head with an R rebound and the lower right hand corner of the paper assembly pan aim towel with a C compression 4 Using a 1 2 boxed end wrench remove the piston nut and washer from the head assembly B2 Place the nut and washer between the R and C on the paper towel B2 5 Remove the rebound disc travel limiter along with the rebound disc Remove stack e
3. Spare poppet parts Part 310 30202 Integra Shock Tools 1 Overflow ring Part 310 30313 2 Rod guide Wrench Part 310 30312 3 Shock Vise Part 310 30204 4 Set of rod clamps Part 310 30206 5 Floating piston locator Part 310 30207 6 Body Clamp Part 310 30311 Tools You Will Need You will need to have the following additional tools equipment to re valve our dampers 1 Nitrogen tank The tank can be purchased at a local gas supply store A small 40 lb tank will likely last you for a full season 2 350 PSI pressure regulator Be sure that the regulator is compatible with the nitrogen gas 3 High pressure hose to interface with pressure regulator and the charging valve assembly 0 6 calipers with English imperial units of measurements Torque wrench with a minimum of 216 in lb capacity 1 2 socket for above torque wrench 1 2 boxed end wrench 4 5 6 7 11 16 open end wrench 8 9 Charging valve assembly 0 Assorted drill bits 025 dia 031 dia 040 dia 055 dia 062 dia 076 dia and 094 dia 11 Paint strainers 12 Tire valve core removal tool 13 Bicycle style tire pump 14 Graduated Cylinder m 47 At age Disassembly Q nitrogen e Clean the exterior of the shock prior to disassembly gas prior to disassembly Discharge nitrogen gas prior to disassembly A1 e Clamp the body of the shock rod end up A2 using the Integra
4. rebound discs onto the rebound disc travel limiter Place the disc stack travel limiter on top of the piston B9 Place the piston washer and nut on the piston rod B70 and torque to 216 in lbs 18 Ft lbs Remove the head assembly from the vice Piston Marked 66 R 37 Piston Marked 66 C 22 Stack compression discs onto disc travel limeter Place piston onto the compression stack Stack rebound discs onto rebound disc travel limiter Place piston washer amp nut on piston rod amp place on piston C1 f Assembly e Be sure all seals are lubricated with O ring lube prior to assembling the unit e Once the head assembly has been completely built the damper can be assembled as follows 1 Clamp the body of the shock in the vice When setting the floating piston to the proper height be sure not to use a high volume pressure source such as an air compressor or compressed air bottle 2 Using the floating piston height tool set the floating piston to the proper setting Remove valve core from tank valve Use a bicycle style tire pump to bump the floating piston approximately half way up into the tube Set the floating piston height tool for the proper damper length See chart for proper setting NOTE Be sure not to use a hard device to measure or adjust the floating piston height as this may cause scratches in the I D of the shock body that could alter the proper perfor
5. D116010 Preload Ring Disk 310 PR128010 Bleed Disk 310 BD4 004 INTEGRA Shock Rebuild SHOCKS ng P a r t S Order TOLL FREE 1 800 472 2464 Integra s complete line of parts makes it easy for you to rebuild and repair your shocks All Integra shocks are e Owner Serviceable eRepairable eRevalvable DESCRIPTION PART PRICE SHOCK VISE Shock Vise 310 30204 169 95 Shock Vise Bench Mount 310 30205 39 95 WTEGRH PART ee ee 310 30202 VALVING KIT me sone PER PART INTEGRA Me Shock Oi 310 30900 1 SHOCK OIL DESCRIPTION PART Inflation Unit 310 30310 PRICE INFLATION UNIT H DESCRIPTION PART PRICE BODY CLAMP Shock Body Clamp 310 30311 49 99 DESCRIPTION PART PRICE WRENCH Rod Guide Wrench 310 30312 27 99 DESCRIPTION PART PRICE OVER FLOW RING Over Flow Ring 310 30313 38 50 DESCRIPTION PART PRICE SPANNER WRENCH C O Nut Spanner Wrench 310 30314 o DESCRIPTION PART 310 30329 PRICE PISTON VISE DESCRIPTION PART Base Valve Tool 310 30901 PRICE BASE VALVE TOOL e Allows valve changing of base valve without removal from pressure tube 4 PART BASE VALVE SNAP RING SLEEVE 310 30331 e For installation of snap ring without damaging pressure tube DESCRIPTION PART Floating Piston Locator 310 30207 PRICE FLOATING PISTON LOCATOR PART FLOATING PISTON TOOL 310 30330 e Used f
6. mance of the shock 3 Seat the tool fully into the floating piston from the top of the disassembled shock body C7 Body Distance from Length top of tube to Center of floating piston g 10 5 8 9 13 16 E 8 15 16 68 A o 7 1 8 4 Press the tool into the shock body until the floating piston reaches the proper height Reinstall the valve core into the tank valve C1 8 5 Pull the rod guide approximately half way down the piston rod C2 6 Fill shock body with oil to the bottom of the internal threads C3 7 Slowly install the head assembly into the shock body Allow time for the air below the piston assembly to bleed past 8 Stroke the head assembly until the air below the piston has completely vented to the top of the shock body Be sure the floating piston does not move C4 Part 310 30310 p CIN INTE GN Assembly Continued 9 Slide the rod guide down the shaft into the shock body Be sure to keep the piston submerged in oil the entire time 10 Tighten the rod guide into the shock body with the rod in the fully extended position Do this slowly so that the air below the rod guide has an opportunity to escape past the threads C5 11 Compress the rod to verify full travel and to be certain the floating piston has not moved during assembly If floating piston has moved piston rod will not fully compress into shock body Damper Recha
7. or air bleeding double adjustable shocks M DESCRIPTION PART PRICE PISTON ROD CLAMP d 310 30206 O NH oreo oro ae ora ooo os8 010 p ooo osseo osez oo roro ae oi 0005210 srroo 000700 eeesio 911 610 ersto 87640 eiro erso serozo ezrozo 821900 Ease TT a E 1 ary PE EE mr sa 0077800 4dozo 911 010 os8 sto 0008900 0001900 0001900 0001 900 0027510 821900 821 900 821400 002 900 Mar U n ooo x unmXy Tao ex zex 08600 zooo 001 900 871 900 orzo 00700 00700 SS Tee UNE Xl al A ooo reio 8215900 ooorero error 0001 800 orkoro 000 010 0008000 0001210 0005210 or1oro 000 800 0001 900 Ee a w www e O 0 Gc L Bulea aqnjouoj prepuejS
8. piston nut and washer 6 Remove all of the discs from the travel limiter amp set the rebound disc assembly travel limiter directly across from the R on the paper towel B3 7 Remove the piston and place on the paper towel across from the piston nut and washer B4 8 Remove the compression travel limiter along with the disc stack from the rod 9 Remove all of the discs from the travel limiter amp set the compression disc travel limiter directly across from 10 11 12 the C on the paper towel B5 Using dial calipers carefully measure each shim s diameter and thickness For rebuilds replace each shim with same size new shim For revalving refer to Valve Code Sheet Note 594 OD x 020 shim is constant and remains on travel limiter at all times Remove shims from paper towel B6 Place the new rebound valve discs on the paper towel directly across from the R and the new compression discs directly across from the C Put the discs in order from top to bottom starting with the disc that will be placed closest to the face of the disc travel limiter B5 13 14 15 16 17 Stack the compression discs onto the disc travel limiter Place the disc stack travel limiter on the piston rod B7 Place the piston on top of the compression stack Be sure to orient the piston properly Face the piston side marked with a C towards the compression valve stack B8 Stack the
9. rging Once the damper has been completely reassembled and the rod guide properly tightened the damper must be charged with nitrogen gas 1 Be sure the valve on top of the nitrogen tank is closed Secure the charging valve assembly to the nitrogen tank regulator 2 Back the pressure regulator on the nitrogen tank completely off 3 Compress the rod into the damper completely 4 Open the valve on the top of the nitrogen tank to approximately 200 PSI 5 Back the wing nut all the way off counter clockwise on the inflation unit part 310 30310 6 Screw the inflation unit onto the damper fill valve Do not over tighten Tighten the valve assembly only enough to eliminate any air leakage D1 7 Turn the wing nut clockwise until it stops This will push in the valve core of the Schrader valve and allow gas to enter the shock 8 Pressurize the shock to the desired pressure through the valve stem on the inflation unit use nitrogen gas only D2 9 Back the wing nut all the way off counter clockwise on the inflation unit 10 Remove inflation unit from the shock You may hear a small amount of gas escape when the unit is removed from the shock If the wing nut was completely backed off this is gas that was stored in the unit and will not affect the setting y Compress the rod to verify full travel in the damper without interference The pressure inside the damper should extend the rod withou
10. t any assistance IF YOU HAVE ACCESS TO A DAMPER DYNAMOMETER BE SURE TO TEST THE DAMPER FOR PROPER OPERATION band REBOUND VALVE STACK COMPRESSION VALVE STACK To order parts call Integra Port City Racing 800 472 2464 Description Part No Retaining Ring Spherical Bearing 310 30328 Spherical Bearing 500 1 D 310 30327 Fill Valve N2 310 30337 310 30301 O Ring End Cap 310 30212 O Ring Floating Piston 310 30213 Floating Piston 310 30334 Adjusting Nut 310 30298 Pressure Tube 5 6 7 8 amp 9 Piston Nut 310 30216 Piston Washer 310 30217 Travel Limiter Disk 310 30335 Piston Digressive Linear High Flow Linear Specify O Ring Piston Band Energizing 310 30215 Piston Band 310 30214 Piston Rod 5 6 7 8 amp 9 Specify O Ring Rod Guide Primary 310 30211 Bearing DU 310 30300 1 Rod Guide 310 30300 O Ring Rod Guide Secondary 310 30210 Rod Seal Quad Ring 310 30209 Rod Wiper 310 30208 Pin Spring Seat Retainer 310 30200 4 Spring Seat 310 30299 Travel Indicator Compression 310 30218 Piston Rod Jam Nut 310 30338 Rod End Housing 310 30402 Backup Disk 310 MVD594020 Valve Disk 70 OD 310 MVD7010 Valve Disk 85 OD 310 MVD85010 Valve Disk 1 00 OD 310 MVD1010 Valve Disk 1 16 OD 310 MVD116010 Valve Disk 1 28 OD 310 MVD128010 Preload Pilot Disk 310 MV
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