I'm in the process of installing the Koni Sports on the front end of my 86 GXL. As you would know if you have installed them, there is a little interesting bit as mentioned on the Koni website:
Ok, so the Koni piece is just a cartridge to fit into the OE housing.. fine.. but it's a tight (press) fit.

The trick is that there are some tabs or raised bumps on the Koni housing that, according to the directions are supposed to make it inside the OE housing.

As I said, it's a press-fit, _before_ you consider the bumps, so I'm a little perplexed as to what my next step should be...

a) Grind off the bumps and push the shock the rest the way into the housing?
b) grind/file out the housing until it's sloppy enough to permit the bumps to enter?

If I do option "a" should I do something about corrosion in the area where the bumps used to be?

ASCII illustration
|||||||
|||||||
/|||||\ <- This bump is supposed to slide into
\|||||/ the OE stock housing
|||||||
|||||||
|||||||

Note: the base of the bump is flush with the rest of the shock diameter, despite the limited ASCII art illustration..

edit: working with ASCII art is phun.. :/

 

Huh, I really do not remember grinding away bumps on mine. I will try to think about that.

I would just say try to push it in.

Here is my write up on the install. Minus the bumps. Sorry

http://pws.gamewood.net/~mb800/struts/struts.html

You will like the Koni. Pain to install but great units. What did you pay for the four?

James

 

Actually, on your install, it almost looks like your bumps don't go inside the OE casing...

At least, judging by this picture:

By the way, the attached image is a modified version of one of yours to point out the bumps I am talking about.

The illustration clearly shows the buimps are supposed to be inside, though.. I'll attach that in a separate picture/post in a few minutes..

 

having trouble posting the pic.

 

I now see what you are talking about. Your arrows worked. I just drove them in there. The big bolt pulled the insert into the body. I did not grind that off.

James

 

http://www7.gamewood.net/~mb800/struts/struts.html

 

That is my install too Sweet, it is everywhere.

James

 

Cool! Thanks for your help and your write-up. Happiness is a working set of shocks (especially if they are konis! :p )..

As for the "nut problem" you mentioned on your page-- my solution was to wrap the shock shaft with an old inner tube from my bike. This allowed me to get a good grip on the shaft (kinda like the "strap wrench" advertised on TV) and keep it from turning while I got the nut in place. I'm not sure if it's that great an idea to advise other people to do (if you have a catastrophic failure of your spring compressors, things could get ugly I guess..).

edit: grammar

 

Glad it is in and working for you! I really enjoy the Koni.

However, I wish they would develop something that does not use the stock strut body.

James

 

So all you guys did was hammer or mallet the Koni inserts into the bodies as far as you could? Then, when you tightened the nut it pulled the insert down the rest of the way?

I gotta get these Konis installed. You emailed me your install pics but they didn't show my issue and the bumps are a problem for me on the Stock KYB bodies.