Wilsons Sandbox

I am tempted to have a go at rebuilding my standard shock, as I cant find a second-hand one and a new one I cant afford. Does anyone have any info on that. Jack Stringer ___________________________ http://www.stringertrailriding.com

Jim Sherlock recently posted about having his stock shock rebuilt. He got a $650 shock by spending $300 on work to his stock unit. It sounds more like you want a $400 shock for $150. I think Works Performance, Racetech, and a few others will do a "heart transplant" on the stock shock for less than $200, but you might not get the same level of customization. If you're rebuilding the stock shock because it's leaking, that's one thing. But if the shock doesn't leak, and you were at one point satisfied with its performance, look into having it serviced. I did this to my stocker, as did Tumu on his previous KLR. Most of the work can be done yourself, you'll need a shop to recharge the nitrogen, and may need the shop to get the spring off. You may to supply an adapter for the recessed schraeder valve, depending on your local shop's ability to improvise. Devon A15 14,600mi stock shock, Prog. LR 500-560 spring, fresh oil and nitrogen at 11,000mi klr650@... wrote:

> I am tempted to have a go at rebuilding my standard shock, as I cant find a > second-hand one and a new one I cant afford. > > Does anyone have any info on that. > > Jack Stringer

Jake Go to the Dual Star web-site and I think they have some new take-offs for around 150.00 Tom K.

----- Original Message ----- From: To: DSN_klr650@yahoogroups.com> Sent: Sunday, July 28, 2002 10:31 AM Subject: [DSN_klr650] Shock Rebuild > I am tempted to have a go at rebuilding my standard shock, as I cant find a > second-hand one and a new one I cant afford. > > Does anyone have any info on that. > > Jack Stringer > ___________________________ > http://www.stringertrailriding.com > > > > Checkout Dual Sport News at > http://www.dualsportnews.com > Be part of the Adventure! > > Visit the KLR650 archives at > http://www.xmission.com/~dkenison/cgi/lwgate.cgi/KLR650/archives/ > > Post message: DSN_klr650@yahoogroups.com > Subscribe: DSN_klr650-subscribe@yahoogroups.com > Unsubscribe: DSN_klr650-unsubscribe@yahoogroups.com > List owner: DSN_klr650-owner@yahoogroups.com > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/ > >

I am from the UK so sending it to the usa for repairs is a bit much. We have had the shock nearly in pieces but there are a couple of sirclips that we are worried might release the high pressure gas. I can get a Hagon shock that would fit mine for 180 or a Ohlins for 280 Jack Stringer ___________________________ http://www.stringertrailriding.com

There are certainly places in the UK that could do a rebuild, or full valving transplant. The list is mostly North American KLR owners so that's the sources suggested. If the Hagon has velocity-sensitive damping, and comes complete with suitable spring and correct bushings, then that's a comperable item and price to the Progressive LR 420 shock. Devon A15 klr650@... wrote:

> I am from the UK so sending it to the usa for repairs is a bit much. We have > had the shock nearly in pieces but there are a couple of sirclips that we > are worried might release the high pressure gas. > > I can get a Hagon shock that would fit mine for 180 or a Ohlins for 280 > > Jack Stringer

well I finally finished testing the rebuilt shock (works great1), and writing and photographing the procedure. For anyone interested, see http://calgarydualsport.tripod.com/klr650shock/procedure.html I'll be upgrading the photo quality as ops become available, but thought I'd post the page now in case anyone is getting ready for the season. Rick Kubik Calgary, Canada ____________________________________________________________ Get advanced SPAM filtering on Webmail or POP Mail ... Get Lycos Mail! http://login.mail.lycos.com/r/referral?aid=27005

Great page Rick,I will set it to Favorites for future reference. Thanks.... Wayne " The difference between an adventure and an ordeal is attitude"(unknown) KLR650A14-1976 R60/6-ABC 6461 MOA-71007

----- Original Message ----- From: "Rick Kubik" To: "DSN KLR650" dsn_klr650@yahoogroups.com>; "KLR Adventure" klr_adventure@yahoogroups.com> Sent: Wednesday, April 16, 2003 12:15 PM Subject: [DSN_klr650] shock rebuild > well I finally finished testing the rebuilt shock (works great1), and writing and photographing the procedure. For anyone interested, see > > http://calgarydualsport.tripod.com/klr650shock/procedure.html > > I'll be upgrading the photo quality as ops become available, but thought I'd post the page now in case anyone is getting ready for the season. > > Rick Kubik > Calgary, Canada > > > ____________________________________________________________ > Get advanced SPAM filtering on Webmail or POP Mail ... Get Lycos Mail! > http://login.mail.lycos.com/r/referral?aid=27005 > > List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Unsubscribe by sending a blank message to: > DSN_klr650-unsubscribe@yahoogroups.com . > > > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/ > >

Excellent work, Rick! I'd like to thank you for this how-to. I was contemplating a $400 rebuild and revalve and cartridge and new spring. But now, just plan to rebuild and respring the leaky pogo stick. Great to have some good info on the gotchas and necessary tools, and sources for parts, etc. Thanks again, very cool, Mark DSN_klr650@yahoogroups.com, "Rick Kubik" wrote:

> well I finally finished testing the rebuilt shock (works great1),

and writing and photographing the procedure. For anyone interested, see

> > http://calgarydualsport.tripod.com/klr650shock/procedure.html > > I'll be upgrading the photo quality as ops become available, but

thought I'd post the page now in case anyone is getting ready for the season.

> > Rick Kubik > Calgary, Canada > >

Great website! Makes me want to disassemble the stock shock I have on my workbench, and maybe install racetech gold valves while I'm at it. One tip- the manual's instructions for removing the shock are rubbish. For some reason, the manual instructs you to unbolt the subframe for pulling the carb or shock, and neither requires it. Here's the easy way- 1- put bike on lift so rear wheel comes off the ground. Put piece of wood under rear wheel to support it. Make sure lift does not block the suspension link from pivoting all the way into the skid plate. 2- Unbolt and remove suspension links. 3- unbolt bottom of shock from linkage. Pull link down/ forwards out of the way. 4- Disconnect crankcase breather hose from airbox, unbolt top of shock. 5- With a little bit of twisting or wiggling, drop the shock out the bottom of the bike. You might have to lift the rear wheel to get a little more clearance. Devon A15 Rick Kubik wrote:

> > well I finally finished testing the rebuilt shock (works great1), and writing and photographing the procedure. For anyone interested, see > > http://calgarydualsport.tripod.com/klr650shock/procedure.html > > I'll be upgrading the photo quality as ops become available, but thought I'd post the page now in case anyone is getting ready for the season. > > Rick Kubik > Calgary, Canada > > ____________________________________________________________ > Get advanced SPAM filtering on Webmail or POP Mail ... Get Lycos Mail! > http://login.mail.lycos.com/r/referral?aid=27005 > > List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Unsubscribe by sending a blank message to: > DSN_klr650-unsubscribe@yahoogroups.com . > > > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/