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Rebuilding Shocks (Read 5941 times)
GPzephyrTurbo
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Rebuilding Shocks
Feb 17th, 2008 at 8:12pm
 
Well after reading the the other post on shocks
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I thought why not., Theres nothing on telly so here I am out in the garage yet again.

Took a shock off my 750 and proceeded to take it apart.

First up take the spring off. I have a pair of car type spring compressors which are really too large for this but with the preload set to minimum it doesn't take much compressing to be able to remove the cup at the bottom.

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With the spring removed I then drilled a couple of small holes (4mm) in the chrome cap under the piggyback section. Using the top of a coathanger twisted around a bit I pulled the cap off with some grips.

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Underneath you'll find a tyre type valve so I took the cap off that and released the pressure inside. There was virtualy nothing in mine.
Next I pushed the bladder thing further in using a socket so it reveals a clip. Prise the clip out with a small flat bladed screwdriver.
Using something on the end of the valve pull the bladder thing out. (I used a right angle adapter I had for getting to hard to reach tyres, but anything like that'll do). There is oil inside so be careful.

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Next up is the main piston assembly. Put the shock in a vice and using a large flat screwdriver and hammer prise the lower cap off. This reveals a load of seals which need pushing in further to reveal another two clips. Get them out using the same method as before and then give the whole piston rod a pull and out it all comes. Hold the shock upright as you do this as there will be oil inside again.

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And thats the disassembly. It took me 20 minutes in all, and it was a whole lot easier than I expected.

Cleaning comes next. My shock is pretty dirty inside and out so will get this done. The old oil that came out was filthy and very little left so the shock never was going to work properly.

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Cant do the reassembly yet as I need to pop by the bike shop and get some more oil.  Cheesy Cheesy

To be continued.............
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Re: Rebuilding Shocks
Reply #1 - Feb 18th, 2008 at 11:31am
 
Good job!
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zr1100uk
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Re: Rebuilding Shocks
Reply #2 - Feb 18th, 2008 at 1:12pm
 
Hi GP,

Your how to is alot easier to follow than the other guys, for me anyway, looking forward to the next part, i bet my shocks will be almost empty of oil as they have been on from new never touched...
Thanks for the how to....Rex.... Cool
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Re: Rebuilding Shocks
Reply #3 - Feb 18th, 2008 at 7:52pm
 
Well done Chris. Smiley

Even Greasy should be able to understand that Wink
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GPzephyrTurbo
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Re: Rebuilding Shocks
Reply #4 - Feb 18th, 2008 at 11:25pm
 
...........Part two.

Im going to use 10W fork oil to do this.

I tried a couple of methods and the best way of doing this is to put the bare shock upside down in a vise. On the shock itself turn the compression damper setting to No4 which restricts the flow between the main tube and the reservoir. (This is setting No1 in the pic, just make sure its on 4)

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Then place a clean bowl (washing up bowl is good if you can sneak it out of the kitchen  Cheesy) under the vise so any fluid that will come out can be saved.
Fill the main shock body up to the top.

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Then push the piston in carefully followed by the seal. Make sure there is still loads of oil, It doesnt matter if it overflows into the bowl, the main thing is to eliminate any air in the shock.

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Relpace the two clips and tap the end bit home.

Next up is the reservoir. Fill this with oil to about an inch off the top. Then put the bladder thing in. Oil will go over the side but this is ok. Push it home as hard as you can with you hand. This is not so easy as mine wanted to pop straight out again. It helps to let a bit more air out of the bladder if required.

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Now it has sealed the reservoir a bit we can put it in the vise with the socket and push it the rest of the way home and put the clip in.

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Take note that on one of my shocks I put just a wee bit too much oil in and wasn't able to push the bladder in far enough to get the clip in, nearly broke my vise. I took a little out and it was fine. doesn't always work first time.

Lastly put the spring back on.

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Thats the general reassembly done. Normally one would need to fill the bladders with pressurized nitrogen. Im not going to use nitrogen, I dont have a handy supply, so Im just going to fill them to 150psi with normal air using a compressor. I'll do that tomorrow.

I'll let you all know if it makes any difference. Undecided  Grin

Chris

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Re: Rebuilding Shocks
Reply #5 - Feb 19th, 2008 at 4:01am
 
Very Nice explanation!!  Smiley
Is it possible to just remove that dust cap and charge up with gas or air without going through the whole overhaul? Just to liven up the shocks a little bit?         -jh
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Re: Rebuilding Shocks
Reply #6 - Feb 19th, 2008 at 8:39am
 
jayhaus wrote on Feb 19th, 2008 at 4:01am:
Very Nice explanation!!  Smiley
Is it possible to just remove that dust cap and charge up with gas or air without going through the whole overhaul? Just to liven up the shocks a little bit?         -jh


Yes it is.

But TAKE CARE as the Schrader valve is machined into the cap and is made from aluminium.

It can break off very easily, as I found out to my horror  Shocked

I had to buy replacement valves, drill out the old ones and bolt in the new.

You can use air instead of nitrogen because the rubber bladder is all that you are inflating, so it will be harmless in there.

By the way - well done GPzephyrTurbo  Smiley
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GPzephyrTurbo
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Re: Rebuilding Shocks
Reply #7 - Feb 19th, 2008 at 1:54pm
 
Took the two shocks around to my Dads place where he has a compressor.
Unfortunately the compressors only rated to 120psi but that'll do.. Plugged the air line in and gave it a burst. As the bladders are small it was very quick. I suspect that releasing the airline has cost me some psi but its still better than nowt. I'd recommend a better method.

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Fitted the shocks back on the bike and went for a short spin.
I find that the damper setting certainly need to be backed off a bit. Whereas before I was running both settings on 4 Now I find I need to back them off to 2, so the damping is certainly working for a change. Cheesy
It'll need a good long run to find the best settings, for now though i'm happy.
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zr1100uk
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Re: Rebuilding Shocks
Reply #8 - Feb 19th, 2008 at 4:44pm
 
Hi GP,

So would you recommend more air than the 120psi you put in, or do you think it is enough, i run a zr1100 are the shocks all set to the same pressure...?
Fantastic  write up easy for me to follow as i'm not a tec head...lol
but do have the urge to learn....
Thanks Rex... Cool
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Re: Rebuilding Shocks
Reply #9 - Feb 19th, 2008 at 5:55pm
 
zr1100uk wrote on Feb 19th, 2008 at 4:44pm:
Hi GP,

So would you recommend more air than the 120psi you put in, or do you think it is enough, i run a zr1100 are the shocks all set to the same pressure...?
Fantastic  write up easy for me to follow as i'm not a tec head...lol
but do have the urge to learn....
Thanks Rex... Cool


Hi Rex
I only got the figure of 150psi off that other write up. Since the shocks are pretty much identical inside thats what I decided to go along with.
Need to really get them charged up properly.


Jayhaus.
I wouldn't think its worth just getting the pressure back in. The trouble is the oil level would have gone down over time and as a result the bladder probably wouldn't be able to act on it.
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Re: Rebuilding Shocks
Reply #10 - Feb 19th, 2008 at 7:46pm
 
Hi GP,

Thanks for that any idea where to get them charged up, im notts based....
Thanks....Rex    Wink
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Re: Rebuilding Shocks
Reply #11 - Feb 20th, 2008 at 9:29am
 
if they needed to be presurised with nitrogen why not try car tyre places as some can fill your tyres up with nitrogen. just a thought.they would probably have enough pressure to do the job?
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Re: Rebuilding Shocks
Reply #12 - Feb 20th, 2008 at 2:19pm
 
So... How much to buy your newly serviced shocks, with mine as part ex?  Wink
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Re: Rebuilding Shocks
Reply #13 - Feb 21st, 2008 at 8:34am
 
I left my piggy back blanking caps off so now I can charge them up anytime.

A plastic seal pushed up inside and around the valve keeps the muck out  Smiley


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Re: Rebuilding Shocks
Reply #14 - Feb 21st, 2008 at 12:14pm
 
Hi HeavenEleven,

Thats a good idea, did you buy the seals and caps if so where from please...? price....?
Or did you make them,... if so how, and what did you use...?

Thanks for the info....Rex... Cool
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