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Old 04-02-2010, 09:19 AM   #1
600k2
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rear shock rebuild questions

I was changing my oil and dog bones yesterday (getting rid of my lowering links, although i did have them set to stock height ) and i decided just for shits and giggles to see how much nitrogen pressure was in the rear shock.

i put my tire pressure gauge on the valve and got 0 psi . so i took a small pocket screwdriver and pushed the schrader valve in and no pressure came out. this cant be good, and i suspect that ive been riding like this since i bought the bike because i never thought to check the nitrogen charge in the rear shock.

honestly, who ever checks the nitrogen charge any way? i even had my suspension setup by a local shop in NJ and they never checked it when they were making adjustments.





Ok, back on topic. I was looking through the manual and it states to remove the rear shock and check for oil leaks. then it states to let all the nitrogen pressure out of the shock. Then junk it?









So, is the rear shock rebuildable even though the manual states that it is not?
Does anyone know how much nitrogen pressure to charge the rear shock to?
Can I just charge my rear shock with nitrogen and be ok until i can afford a better aftermarket rear shock?

thanks!
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Old 04-02-2010, 09:24 AM   #2
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Re: rear shock rebuild questions

and its probably not a bad idea for you other Y2K gixxer owners to check the nitrogen charges in your shocks. when is the last time you checked yours?
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Old 04-02-2010, 10:55 AM   #3
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Re: rear shock rebuild questions

i found some info here and was wondering if anyone can back it up.

http://www.riderforums.com/showthread.php?t=15342

175 psi for nitrogen and 125 for air (im not going to use air in mine)

sound right??



this is what i am looking to do to my shock...
http://pnwriders.com/general-discuss...hock-sale.html

does anyone know where to get parts for these shocks? apparently they CAN be taken apart/serviced. I need a hook-up for upgrade/rebuild parts




EDIT: i see that Racetech offers parts to rebuild shocks. is it worth it? any experience with racetech anyone?

http://new.racetech.com/HTML_FILES/GVCONVERSION.HTML

Last edited by 600k2; 04-02-2010 at 11:14 AM. Reason: added more text
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Old 04-02-2010, 12:58 PM   #4
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Re: rear shock rebuild questions

I got mines rebuilt w/ racetech gold valve for like $100. To tell you the truth the racetech stuff is a cheaper investment than an ohlins/penske. Although in the near future, I will be upgrading to a fully adjustable shock like the ohlins/penske stuff. It's a bit pricey, but I'm sure it is worth it.

Last edited by Chugs; 04-02-2010 at 01:02 PM.
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Old 04-02-2010, 02:42 PM   #5
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Re: rear shock rebuild questions

Not the same bike, I know, but I rebuilt the shock on the Busa a couple of years ago with Racetech stuff.

If I were you, I'd get on their site and see what they say about it and if they can, send it in to them to rebuild for you.

You'll have to set it up when you get it back but a little reading and you'll be good to go.

You may want to just do the whole thing and get the forks done at the same time unless you just recently did them.

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Old 04-02-2010, 02:50 PM   #6
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Re: rear shock rebuild questions

forks are next on the list, they were first but then i noticed that there was no nitrogen in the rear shock. im still looking for a left front fork so i can have another set

i am going to do all the work myself because i want the experience.

i dont think the forks or the shock have ever been done in 8 years and 22k miles
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Old 04-02-2010, 03:36 PM   #7
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Re: rear shock rebuild questions

Quote:
Originally Posted by 600k2 View Post
forks are next on the list, they were first but then i noticed that there was no nitrogen in the rear shock. im still looking for a left front fork so i can have another set

i am going to do all the work myself because i want the experience.

i dont think the forks or the shock have ever been done in 8 years and 22k miles
It's a fun job. You'll learn a lot about it, believe me!

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Old 04-02-2010, 03:39 PM   #8
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Re: rear shock rebuild questions

Quote:
Originally Posted by Chewee View Post
I got mines rebuilt w/ racetech gold valve for like $100. To tell you the truth the racetech stuff is a cheaper investment than an ohlins/penske. Although in the near future, I will be upgrading to a fully adjustable shock like the ohlins/penske stuff. It's a bit pricey, but I'm sure it is worth it.
Even better find a used Ohlins for a decent buy and then send it to Racetech to be sprung for your weight
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Old 04-02-2010, 03:41 PM   #9
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Re: rear shock rebuild questions

Quote:
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Even better find a used Ohlins for a decent buy and then send it to Racetech to be sprung for your weight
Positively brilliant idea.

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Old 04-02-2010, 03:48 PM   #10
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Re: rear shock rebuild questions

Quote:
Originally Posted by Wag View Post
Positively brilliant idea.

--Wag--
I paid $150 for my used Ohlins r shock and the Racetech rep said for another $150-$200 I could send it out to be resprung and valved and they would have it back to my door within a week.
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Old 04-02-2010, 06:38 PM   #11
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Re: rear shock rebuild questions

Quote:
Originally Posted by Revzilla View Post
I paid $150 for my used Ohlins r shock and the Racetech rep said for another $150-$200 I could send it out to be resprung and valved and they would have it back to my door within a week.
That's a great deal, I've been looking, haven't found any great deals like what u paid for yours.
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Old 04-09-2010, 07:36 AM   #12
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Re: rear shock rebuild questions

Continued....(if someone wants to buy me a digital camera..feel free)

I got a rear shock from Gfunk. i was planning on swapping my rear shock for his until i got around to rebuilding mine. Gfunk's shock had no nitrogen in it either...it pushed the whole diaphram in when i went to check the pressure.


where it should be


how it pushed in


so i guess im going to be doing this asap. i started to take the shock apart.

i used 2 ratchet straps to compress the spring


then you can loosen the jam nut, then the spring adjusting nut


lift the spring and plastic protector up, and you will see the bump stop


during the teardown, i got this much sand out of the shock, about 3 different times! every time i swept the work bench and did another step more sand came out...


under the bump stop there is a 22mm nut


you can gently knock the lower spring seat with a hammer (kinda corroded on there) and get to that nut easy
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Old 04-09-2010, 07:37 AM   #13
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Re: rear shock rebuild questions

nut and bottom mount removed


remove the rod for the adjuster


break time!


i took out the diaphram next, this snap ring is a PITA.


removed


oil was coming out of the shock from where the diaphram was. i put it in a container.


held up to the light


organized parts and drained all the shock oil out into the container. i worked the shock in and out and was able to get all of the oil out through where the diaphram came out of


bottom of shock, hammer off cap
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Old 04-09-2010, 07:38 AM   #14
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Re: rear shock rebuild questions

under cap is another snap ring


i removed the other adjuster on top with a 17mm wrench
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Old 04-09-2010, 07:41 AM   #15
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Re: rear shock rebuild questions

after removing the snap ring i could not pull the shock internals out easily because the o-ring was caught in the ring land for the snap ring.


i need a vice...




so i got the shock body mounted to the table and gently hammered the internals out


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Old 04-09-2010, 07:45 AM   #16
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Re: rear shock rebuild questions

remove the nut on top, mine came off hard the whole way.


dont lose any shims. i prefer zip ties.

this is where i got stuck because the threads are a little screwed up. this valve should slide off but gets caught on the last 2 threads. that nut came off hard and must have damaged the threads a little. this is where i stopped for now.


the last steps would be to slide off the valve, other shims, and washer.


im ordering some racetech parts later. when they show up i will finish.
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Old 04-09-2010, 07:47 AM   #17
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Re: rear shock rebuild questions

Quote:
Originally Posted by 600k2 View Post
i dont think the forks or the shock have ever been done in 8 years and 22k miles
Have fun with that - I rebuilt a set of forks that had never been done, bike was about 10 years old and had ~30K miles on it. The fork oil had been reduced to a black slush that smelled like sewer uke
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Old 04-09-2010, 07:52 AM   #18
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Re: rear shock rebuild questions

im expecting sludge...
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Old 04-09-2010, 08:00 AM   #19
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Re: rear shock rebuild questions

Quote:
Originally Posted by 600k2 View Post
i found some info here and was wondering if anyone can back it up.

http://www.riderforums.com/showthread.php?t=15342

175 psi for nitrogen and 125 for air (im not going to use air in mine)

sound right??

#1. i need someone to verify that the nitrogen charge is 175 psi. any help?

#2. also, for refilling the shock, do i want to get all the air out? should it be like when you do the steering damper mod..get all the air out? OR should i measure the volume of old shock oil and put in the same amount?

Thanks
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Old 04-09-2010, 09:44 AM   #20
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Re: rear shock rebuild questions

sweet thread, I know where the sand came from
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