87 KDX Rear Shock Lower Clicker Bind?

[Joe87KDX]

Hi Guys I am in the middle of rebuilding my rear shock on my 87 KDX200. When I go to install the shock shaft into the lower clevis, it is causing the clicker bevel gears to bind. I am thinking that there should be a washer in between the clevis and the shock shaft to provide correct lash between the gears. See picture below. I can't find any exploded diagrams that show the individual pieces of the shock shaft/clevis assembly. Can anyone confirm if there should be a washer here and if so, do you have any dimensions (specifically thickness)?

Is there something else I might be missing?

[KDXGarage]

SEXY!! What did you do to the clevis, Cerakote??

Cool that you have a Gold Valve. Cool spacers to get the height right, too. Are you just making your best guess on the valving? I thought about putting one in mine years ago, but never did. Cool to see someone do it.

On to your question and not me just looking at the shiny, pretty picture. Are you sure the rod, o-ring and such are all good on the inside? Was it working well before? Is there an issue on when the adjuster and needle installation order? I have not taken one apart to that level.

Thank you.

[Kipsy]

Here's a pic of an old 87 shock I had laying around. I doubt it's ever been opened up. It appears to have no washer.

How did you decide which gold valve to buy? I'd also like to know how you got the valving. I'm starting working on a pair of C-Series bikes right now and I'd like to do a Gold Valve in one of them, as I'm going to run a stiffer spring in one.

[Joe87KDX]

Thanks for the reply KDXGarage and Kipsy! Kipsy, your picture was just what I needed. A little further investigation led me to find some chipped gear teeth inside the clevis. I thought everything was operational prior to disassembly. So, either I missed it or somehow broke them trying to assemble the shaft into the clevis. Regardless I've got some investigating to do, and I need to acquire another shock / clevis that I can pull some parts from.

Yes, the clevis is Cerakote.

Regarding your questions about gold valve, here is what I've got: The part number is SMGV 401602 from Race Tech. This gold valve kit comes with an assortment of shims and access to their online DVS valving system. I enter my rider weight, terrain, skill/speed level, etc. into the DVS sheet online and they provide a full shim stack for compression and rebound using what's available in the kit. We'll see how close it is whenever I get the bike done.

I did run into one issue which revolves around KDXGarage's comment on my spacers. The kit includes two types of shaft nut, a standard type and a special nut with built in shim locating shoulder. The standard nut didn't get enough thread engagement and the special "shoulder nut" bottomed out before tightening down against the shim & valve stack (there was a ~5mm gap! I ended up machining the shoulders off of one of the additional shoulder washers included plus more spare shims to get the proper thread engagement. Below is picture that hopefully helps.... clear as mud right?

[KDXGarage]

T-hank you for the info. Years ago, they just showed "Call Race Tech" for custom valving and they did not offer a kit marketed for the 86-88 KDX200. One thing I would suggest on any super build is that I read 1988 and older shock bodies are not hard anodized like the 1989 and newer shock bodies.

[pkenney]

Hate to thread-jack but wondering if there is a way to get the clicker assembly out of the clevis. My KDX has been sitting for a few years and the shock was down to about 50psi. I am taking it out to rebuild it and see the top of the shock is covered in black goo. Bottom of the shock is clean so the seal head is OK. Last time I rebuilt it I did not take that assembly out since there is a plug driven in. do you need to take the clevis off the shaft to get it out??

BTW, on the clicker, I have an old shock with the upper bearing out and see that there is a pin that moves in and out when the clicker is rotated. It can extend into the bearing bore if you turn it far enough. I have 2 old shocks that aren't in too bad condition if you end up needing a clevis.

[pkenney]

BTW, did you mean "upper" clevis??? or do I have my shock mounted upside down?