Rebuilding Koni Shocks

[bikerphil]

Ok, I picked up a set of Koni shocks with adjustable rebound damping for the XS11 off Ebay for $15. I'd like to change the oil in them as they feel a bit mushy. The seals are in good condition, but I'm trying to figure out how to get them open. It looks like a special tool is needed to unthread the cap, similar to a tool used for changing a grinding disk. I don't want to bugger up the caps with a vise grip, so does anyone know if a tool is available like this or some advise on how to make one. Center to center, the holes are 0.90" (23mm) apart. I'd appreciate any help.

[bikerphil]

Ok, I think I figured this out. Went to Ace and bought some of those hardened dowl pins and fabricated my own tool...





Got the shock apart and measured the volume of oil that came out, 75cc's.





Next, I checked the viscosity of the oil with a painter's funnel, timed at 12 seconds, which appears to be 5W oil...



Gonna put it all back together with 80cc's of 10W suspension fluid and we'll see how it goes.

[Cobia]

Keeping Busy...

Keeping busy today??? Love those projects..

[crazy steve]

...It looks like a special tool is needed to unthread the cap, similar to a tool used for changing a grinding disk. I don't want to bugger up the caps with a vise grip, so does anyone know if a tool is available like this or some advise on how to make one...

HF sells an adjustable one; they call it a 'pin wrench'....
http://www.harborfreight.com/adjusta...nch-36554.html
Great tool, I use mine all the time; works better than the 'supplied' wrenches that come with grinders, and fits any brand/model.

[bikerphil]

HF sells an adjustable one; they call it a 'pin wrench'....
http://www.harborfreight.com/adjusta...nch-36554.html
Great tool, I use mine all the time; works better than the 'supplied' wrenches that come with grinders, and fits any brand/model.

Yep, that's what I need Steve, thanks for that link. Think I'll pick one up.

Ok, I got one shock back together with 10W and it feels much better with the new oil. Rebuildable shocks are king.

[bikerphil]

I finished refreshing both shocks with new oil, took them for a test ride, and I must say 100% improvement. Much better damping with the thicker oil.

[Rickrod3]

Stuff you learn here is priceless

Another good one Phil

[bikerphil]

Thanks, Rick. Anything to improve the XS a bit. I've noticed some real quality shocks can be found on ebay lately for cheap, if you know what you're looking for. A lot of them are listed by dismantlers as XS11 stock shocks, they just don't know what they have. I've recently bought a set of S&W street strokers for $20 and the Koni's for $15. It's amazing how setting up the rear suspension correctly contributes to how the front reacts.

[somesuch]

Check the top-out bumper inside.....those get old and disintegrate clogging up the piston.

--Nick