I have the new Koni’s on the rear, today started on the front, JB weld on the perch ring last week. Today started on the new springs, compressed them but the cap will not expose the rod threads! Removed the spring, tried the cap and still the threads are not exposed.

Shock and lower perch with rubber bumper

Dust cover added

Big washer form the upper cap

Washer and upper bushing

Upper bushing with washer and plate

Plate on shaft, no threads,shaft even with plate

Added big top washer and threads not usable?
so the rear shocks went on OK, but even with no spring the treads are not exposed?
What now?

 

Solution! The dust cover does not go all the way down! The Boge shock has a slightly smaller diameter shaft and the dust cover goes all the way down. The Koni shaft is microns larger and that keeps the boot from going all the way down. So I will try new boots and see if they fit, these original ones are showing cracks so better to use new ones.

 

You will need to slightly enlarge the hole in the aluminum part of the dust cover to allow the dust cover to fit correctly onto the shaft of the Koni. I think that the later incarnations of the dust covers features a very slightly smaller hole that the shaft of the Koni cannot accommodate without being enlarged. It wasn't always that way. The older dust covers would fit just fine, the newer ones not so much.

 

Well I have two new ones on the way, and now know what the issue is.