Rear shock rebuild..any special tools needed? /project thred

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Gotanubike
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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 11:06 pm Jan 19 2014

So since I bought the bike it's basically been a pogo stick..It's like riding a bucking green bronco on the track. Nobody wants to ride it :sad: The rear shock is completely unresponsive, so it's just riding on the spring. Also really black sooty oil leaks from the valve stem when i check with the pressure gauge. I suspect it will need bladder seals(or whole new bladder?), new oil and possibly piston seals in the shock..

I see the procedure for removing the shock is fairly simple...I was sure I would have had to remove the swing arm, brakes, chain, etc..

Are there any special tools needed to disassemble and rebuild the shock? Will it be worth it just to remove it and have it professionally serviced?

Thanks :supz:
Last edited by Gotanubike on 06:02 pm Jan 20 2014, edited 1 time in total.
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Re: Rebuilding a rear shock..any special tools needed?

Post by royadams » 07:03 am Jan 20 2014

You can not check the pressure in the rear shock..there is a small amount of nitrogen in there any attempt to check it will let it out leaving it very low and useless. There are many videos on you tube that show how to service it. Then you will need to bring it to have to shock filled with nitrogen.

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Re: Rebuilding a rear shock..any special tools needed?

Post by bufftester » 09:52 am Jan 20 2014

No special tools are needed, they are fairly easy to take apart and service. Take your time cleaning the shock before you start, and while you work trough it, that's one of the keys to success with shock rebuilds. Parts are easy to come by. If you're getting oil at the valve stem you probably need a new bladder. The only part you can't do is recharge the bladder with nitrogen, but any shop can do it for a nominal fee (it was 5$ at my LBS).

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Re: Rebuilding a rear shock..any special tools needed?

Post by Postigo » 10:31 am Jan 20 2014

Hi, is pretty simple if you are mechanically inclined. I bought a complete rebuild kit from Jason last year. Here is a video from rece tech: http://www.racetech.com/page/id/138 :supz:
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Rebuilding a rear shock..any special tools needed?

Post by Gotanubike » 01:49 pm Jan 20 2014

Ok great video, I'll bookmark that page for when I start...

And for parts, are there any recommended aftermarket kits are available for the E series, with all the o-ring seals, bladder, bottom out bumper? Or should I just get OEM from the dealer?
royadams wrote:You can not check the pressure in the rear shock..there is a small amount of nitrogen in there any attempt to check it will let it out leaving it very low and useless. There are many videos on you tube that show how to service it. Then you will need to bring it to have to shock filled with nitrogen.
Yeah it's only considering the shock was a dead duck anyhow I figured I couldn't make it any worse....I mean there is NO shock compression or rebound on this bike. It's %100 spring :lol:
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Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
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Rebuilding a rear shock..any special tools needed?

Post by Gotanubike » 05:33 pm Jan 20 2014

I got the shock off and I may be dumb for not mentioning it, but the reservoir has a pro-tech sticker on it...Also I noted that the number of clicks on compression adjustment was 23 and 26 on rebound...my manual says usable range is 16 clicks for both top and bottom...Is this an aftermarket shock??

edit: I just did a search and found they are a suspension servicing company in London, On...previous owner must have a had it serviced there....

Image

Here's what I drained from the reservoir valve (right side up) :vom:

Image
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Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 06:33 pm Jan 20 2014

Doing some cleaning up around the bottom linkages and I uncover this...Looks like I may just be in for a complete shock replacement :evil:

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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 07:33 pm Jan 20 2014

And finally, getting the sir-clip and bladder cap off was not easy...I actually used the electric lighter pump in the car and popped it out with pressure...


Low and behold...the bladder had a big hole in the very top....cleaned it up and checked with a flashlight and you can see light penetration...To the admins, Sorry I'm probaby not making it any easier on the servers hosting all these pictures :mrgreen:

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Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
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Rear shock rebuild..any special tools needed? /project thred

Post by KDXGarage » 08:30 pm Jan 20 2014

Riding it like it was surely destroyed it. Buy a used one and rebuild it.
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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 08:43 pm Jan 20 2014

yeah well what can I say, It's likely been like that much longer than I've owned it...I bought the bike back in May and never rode it very hard over the summer
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Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
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Re: Rear shock rebuild..any special tools needed? /project t

Post by KDXGarage » 08:55 pm Jan 20 2014

Oh well, just get another one off ebay.

EDIT: Here is a picture of the shock parts of one I worked on.

Image
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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 10:30 pm Jan 20 2014

That's a great exploded view, i found that one over at thumpertalk too
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Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
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Re: Rear shock rebuild..any special tools needed? /project t

Post by Goofaroo » 10:36 pm Jan 20 2014

The yoke is probably cracked from topping out violently while being ridden with no dampening. While you're waiting on a new shock you should take a close look at your linkage also.

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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 04:15 pm Jan 21 2014

Can anyone confirm the KX500('97-'04) uses the same rear shock as the KDX200?? I found many bladders with 97-04 kx500 and 04-05 kx250f listed as compatible without kdx200 or 250 listed, but in the diagrams all have the same part # and basically the all the same suspension parts minus a few little things
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Rear shock rebuild..any special tools needed? /project thred

Post by KDXGarage » 09:14 pm Jan 21 2014

Gotanubike wrote:That's a great exploded view, i found that one over at thumpertalk too
Thanks. I am over there too.

I think you are probably looking at JUST the first 5 digit of the part number, not the complete part number.

The bladders are the exact same part, however. The shocks are not.

It is an 88mm long KYB brand bladder.
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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 09:29 pm Jan 21 2014

I know, I've ordered lots of stuff from my dealer, they need the whole 8 digit number with the dash

I ordered this one, as it was the best price i could find. They are $60+ from OE dealer

http://www.pivotworks.com/ProductInfo.a ... m_id=52603

Doesn't specifically say 88mm but if you search the part number(120104600101) elsewhere you find retailers selling it listed as 88mm....no mention of kdx200/220/250 compatibility on any I found tho :hmm:
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Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
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Re: Rear shock rebuild..any special tools needed? /project t

Post by KDXGarage » 10:02 pm Jan 21 2014

Why did you order a bladder? Surely it is not going in the shock with the cracked clevis, is it??
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Rear shock rebuild..any special tools needed? /project thred

Post by Gotanubike » 10:12 pm Jan 21 2014

My brother's going to have a look at it, he does a bit of welding at work..if it can't be saved I'll have to purchase a new piston assembly with that linkage
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Re: Rear shock rebuild..any special tools needed? /project t

Post by KDXGarage » 10:55 pm Jan 21 2014

Just buy a used shock off ebay.
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Re: Rear shock rebuild..any special tools needed? /project t

Post by bufftester » 09:51 am Jan 22 2014

Jason wrote:Just buy a used shock off ebay.
+1
For what you spent on a bladder you probably could have found an entire shock (saw 3 on Ebay this morning for under 100). I'd be nervous about repairing that and riding it. Not a lot of surface to work with, and that piece takes a beating (obviusly).

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