Rear shocks overhaul

[lawrie]

Any of you experts out there ever stripped these units??

If so, whats the secret of getting that bloody spring circlip out from the pump-body, took me a full day, that thing was NOT meant to be removed, & I very nearly ended chucking in the bin!!
The jack-screw was stripped, but all ok now as I have made new parts.

[lawrie]

ANYBODY?

Ok, so maybe no-one has delved-in this far.
So this is what I did just in case any others need to do this.

I got hold of a pair in need of a re-furb, basically good condition, but they each had a different problem with the adjusters ( as usual )
One had its adjuster just rotate with nothing happening, the other had the knob missing, & that too wasn't right.
Anyway, both were taken apart only to find one pump jack-screw completely stripped & the other was wound out past it limit & the retainer was forced off & the innards were loose inside!!
I'm pretty sure these units are not intended to be dismantled as the internal wire spring-clip is snapped into a blind recess with no way to get behind it for removal, so I thought I had nothing to lose by a bit of (sorry) butchery!!
Suffice to say they were eventually removed & stripped, one screw was stripped beyond repair so it had a new jack-screw made, & the end cap was re-coiled, 4 new jack 'O' rings, 2 new piston 'O' rings & 2 replacement adjusting knobs were made, a bit of tarting up, re-assembled & fitted, look good, work good so all is good!!
https://www.dropbox.com/s/yzndk5ro4r11obj/RearShock16.jpg?dl=0

[bigfathairybiker]

Hi,

I will be stripping a set of ohlins piggys from an old cb750f2n soon.
Basically the same as the gsx shocks but without the adjusters.
I will report my findings with piccys.
Then once I've sussed em, I'll do the same to the gsx.

But... I think your talking about an internal circip without eyes?
I've removed these using a three screwdriver method. One stops the ring rotating. One to prize out one end and one to use as a lever.
I had to file down the tips to fit and also use several as levers just like you would remove a tyre from a wheel.

Mark

[lawrie]

Hi Mark, you're spot on about the circlips, however, it this instance things are different, 'normal' clips are positioned level with the retainer-plate so removal is simple & i've done loads, BUT, here the clip-groove is BELOW the plate & there is an annular groove around the top-face of the plate & on assembly its hard pressed into place & its then not accessible,  since it below the plate, there's no-where to pry the clip out.

If its possible, i'll do a CAD drawing & post it, you'll see the problem then.

[lawrie]

Don't know if it works, but if it has, the 2 uprights are the cyl wall, the top cross piece is the normal way circlips are fitted, the lower one is the way our clips are fitted, you can see how difficult it is to pry it out.


https://www.dropbox.com/s/tkfr6c92j7m7t13/CirclipInBore.jpg?dl=0

[VladTepes]

You're a talented guy lawrie !

[bigfathairybiker]

Is this the circlip in the air reservoir?
If so the plate should push down allowing full access to the circlip.  As should the piston in the main  shock.
After releasing the air that Is...


Mark

[lawrie]

No, it holds the end-plate of the oil jack, if the black plastic adjusting knob is removed, the plate & circlip is revealed, trouble is, the plate is hard down onto a 'ledge' & can go down no further, hence the difficulty in removing it.
I didn't put enough detail on the drawing & did not show the 'ledge' but it can be seen in pic 5 , where you can see the ledge down the bore, & the plate & screw are at the top of the pic.

As for the 'air' there ain't none!!   Its nitrogen & it under high pressure, so I personally would make no attempt to release it, & even then, I don't have the necessary to re-charge it.
Just try & 'crack' the bottom mount-eye by the thumb-wheel to see what happens, it scared the bejeesus out of me.  

[lawrie]

No, it holds the end-plate of the oil jack, if the black plastic adjusting knob is removed, the plate & circlip is revealed, trouble is, the plate is hard down onto a 'ledge' & can go down no further, hence the difficulty in removing it.
I didn't put enough detail on the drawing & did not show the 'ledge' but it can be seen in pic 5 , where you can see the ledge down the bore, & the plate & screw are at the top of the pic.

As for the 'air' there ain't none!!   Its nitrogen & it under high pressure, so I personally would make no attempt to release it, & even then, I don't have the necessary to re-charge it.
Just try & 'crack' the bottom mount-eye by the thumb-wheel to see what happens, it scared the bejeesus out of me.
No, on second thoughts, best NOT to try the above, I'm a loony, &  don't wish to be responsible for your blowing-up.

[bigfathairybiker]

Ok. I see.

Air/nitrogen... don't really matter too much as air is 80% nitrogen!
100 to 200psi... usually.. no harm in letting it out.  But you then have to pump it back up!

I've started the disassembly of the showa shock I have. Gone well so far. But only one circlip  in air reservoir.

Mark

[GeorgeHutchinson]

Hi lawrie

I'm new to this forum malarky, so early apologies if I don't follow etiquette.

I've just bought a pair of K5 shocks with intention of refurbing them myself, so was interested to see your post.

I'd be very interested if you have any photos of the dismantling/rebuilding process.

[seth]

hiya George
have a good look through the furom as quite alot of info on rebuilding/refurbing the shocks.
if you get stuck just ask .

[GeorgeHutchinson]

Thanks Seth

Had a good look around, but nothing much in the way of photos of the dismantling process, or the internals. I just don't want to wade in and butcher the whole lot!

I've already been through the o-ring replacement repair on a pair of K3 shocks off my own bike. Got the springs powder coated while I was at it.

I got these K5 units cheap enough to try playing around with them.  The compression asjuster has seized on one unit and need a good tidy up, but they seem fine otherwise.

Would be great if someone would have photos or info on the re-gassing process.

😎

[Simonic]

[quote ] if the black plastic adjusting knob is removed
[/quote]
What holds the knob in please ?

[KiwiCol]

Not sure what holds it on, but a 4lb sledge & a cold chisel gets it off . . .