Author Topic: kdx rear shock rebuild (Read 7384 times)

kdx Geoff · « **on:** December 16, 2013, 11:37:36 am »

Hi,

l have and 83 kdx250 rear shock that's leaked and would need a rebuild, any recommendations as to who can do this and what it might cost ?

Do they have any consistent issues l should be aware of ?

Thanks

kdx Geoff

AdamN · « **Reply #1 on:** December 16, 2013, 12:40:02 pm »

Hi Geoff,

get a Kawasaki manual as it explains how to pull the shock down. Get some 5wt oil, o rings and bush from EBay and do it yourself. Take it to get charged and you are done. It's not big or daunting job if you have the basics.

Cheers
Adam

kdx Geoff · « **Reply #2 on:** December 16, 2013, 07:07:58 pm »

Thanks Adam, l may have been a tad premature, l now have the shock out of the bike and looks like the shaft is rooted, what's the are my options for replacements, a used shock off eBay ?

80-85 husky · « **Reply #3 on:** December 16, 2013, 07:10:42 pm »

a rechrome may be possible Geoff, talk to Mick at Bgo dirt bikes, he will know who can recrome the shaft. (if u cant get a good shocker) they should be a std KYB of that era so some one will know the best way forward for you.

JohnnyO · « **Reply #4 on:** December 16, 2013, 07:35:27 pm »

Geoff your shaft can be rechromed at Rad in Brisbane. I can rebuild your shock with a new seal head, oil, gas etc. I'm a full time motorcycle mechanic and do a lot of suspension work from home.. Up to you

Davey Crocket · « **Reply #5 on:** December 16, 2013, 08:06:30 pm »

Send it to JohnnyO, he's local, a good guy, knows his shit and he's bought one of your clutchcovers for a CR.

oldfart · « **Reply #6 on:** December 16, 2013, 09:05:11 pm »

Joan ..... I think it's time to take your medication again

seems you have the KDX's mixed up

kdx Geoff · « **Reply #7 on:** December 17, 2013, 10:38:14 am »

Thanks.

l have a shock out of a 200, I'll see if that fits to get the bike mobile and as l have a manual, strip the old shock and see how bad it is.

kdx Geoff

Nathan S · « **Reply #8 on:** December 17, 2013, 11:51:06 am »

200 shock has a softer spring. May be slightly shorter. May have a different lenght hose to the reservoir (depending on whether it was from an A or B model).
Will fit and work, in any case.

kdx Geoff · « **Reply #9 on:** December 17, 2013, 06:00:12 pm »

For those who like detail....

7/85 200 5/83 250

They share the same overall length at approx. 425mm and damper diameter at 45.5mm.

The reservoir hose is a bit longer on the 200.

The spring on the 200 is 10.7mm and 11 coils.

The spring on the 250 is 10.9mm and 12 coils.

The 200 damper and the 250 spring look good, there's likely to be 1 good shock between them.

l just bought the 200 as a rolling frame and a box of bits a couple of weeks ago and was not thinking l bought well and had a bit of a complain, looks like l was wrong

kdx Geoff

kdx Geoff · « **Reply #10 on:** December 17, 2013, 08:12:43 pm »

Quote from: Wasp on December 17, 2013, 06:04:26 pm

Quote from: kdx Geoff on December 16, 2013, 11:37:36 am

Do they have any consistent issues l should be aware of ?

Thanks

kdx Geoff

Geoff , like all Alu shocks , the chances of a worn bore are very high . I have 40 mm steel conversion kits if you need it . ( Also 36 mm , 46 mm and 50 mm ) but I think yours are 40 mm .

Thanks, I'll get it apart and see how it looks

kdx Geoff

Nathan S · « **Reply #11 on:** December 17, 2013, 09:35:11 pm »

For whatever reason, the old Kawi shocks seem much less prone to wearing the inside of the body than (say) old Yamaha shocks.
I guess the UniTrack design takes out more of the side loads, and they do have a thick walled body which better resists ballooning.

You'd never bet the house on the body having no wear, but for these shocks, the odds are better than even that the body will be servicable.

Paul552 · « **Reply #12 on:** December 17, 2013, 09:44:25 pm »

Is a shock the type of thing you can do yourself?
They look simple but are they?

I have a spare I was thinking about having a go at

80-85 husky · « **Reply #13 on:** December 18, 2013, 06:53:23 pm »

usually need a special tool or two to get them a part but then its easy if the parts are available. the critical point is keep everything in order as you pull them apart. send it to someone.... that's my advice

kdx Geoff · « **Reply #14 on:** December 22, 2013, 02:19:59 pm »

The 250 damper is apart and to this point its straight forward.

The inside of the body looks like this....

You can see a couple of marks on the bore around 3 o'clock. l didn't think they would be excessive for a 30 year old bike.... l was going to do a light hone with some lubricated wet and dry on a drill, is that acceptable for aluminium or is that a hardened working surface ?

Is this the best way to replace the shaft seal ? this is an assembly for a 200, says it wont fit a 250.

http://www.ebay.com.au/itm/400628965092?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

Thanks

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