1980 GL1100 air shock rebuild. New springs. Need guidance

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Airshow
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1980 GL1100 air shock rebuild. New springs. Need guidance

#1

Post by Airshow »

I am rebuilding a set of air shocks off of a 1980 GL1100 for a project I'm working on. The new springs and seal kits came from Progressive. I also ordered two new internal bumpers. I have read all I can find on the process and watched several videos with interest.

So far so good until I started to reassemble the components.

The new inner spring does not fit into the sleeve like the old spring (see photo).

The outer spring in fine.

Thoughts, suggestions. Thanks.
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Re: 1980 GL1100 air shock rebuild. New Progressive springs/s

#2

Post by Airshow »

Parts list
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#3

Post by Track T 2411 »

I've not done this fix (yet) so my opinion is based on only what I can see in your pictures. It looks as though the issue is only a tight fit in the sleeve, is that correct? When assembled, I can't see that there would be any chance of (or reason for) movement of the inner spring within the sleeve. IMhO, enlarge the inner diameter of the sleeve using sandpaper or the like just enough to allow free movement of the new spring. Try to keep it even, and get it as smooth as possible.
I wouldn't doubt that Progressive has a tech support line or email contact, and this would probably be a common issue. You might check that out first... My 2 cents...
"I have no special talent. I am only passionately curious." - Albert Einstein

"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.
Airshow
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#4

Post by Airshow »

Thanks for your suggestions. After repeated calls/messages, and email to Progressive with no response, I moved on to enlarging to ID of the sleeve. A combination of removing material, leaving the springs overnight in the freezer and setting the sleeves in the warm CA sun resulted in the springs slipping right in. They weren't going to mate without the hot/cold. I won't call it an interference fit, but it's TIGHT.
Thanks again.
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#5

Post by 82aspy »

oil seals fit ok? I think they are supposed to be 1100 -1200 suitable? and even Progressive Suspension 416 series air shocks
"there is a Darwinian element"
Yoda said, "There is no try or not try; there is only do or don't do."
=====================
ngw quotes anim-cheers1 - \ "I will strip the beast" \ "the swingarm is just a hunk of metal" \ "gonna maybe ...dunno yet" \ "It's never done, thats the fun." \ "something about this site brings me back"
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#6

Post by Airshow »

82aspy wrote:oil seals fit ok? I think they are supposed to be 1100 -1200 suitable? and even Progressive Suspension 416 series air shocks

Yes. They measured out fine. As soon as I polish the top lug mounts I'll reassemble them.
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#7

Post by Airshow »

Today was polish day. I have three bike projects going on at one time so polish, polish, polish. Top of the list was the top of the GL1000 air shocks. Everything will go back together on Monday.

The second photo is before and after cleaning/wire brushing.
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#8

Post by 82aspy »

:shock: :shock: :?: :?: :orange :orange
"there is a Darwinian element"
Yoda said, "There is no try or not try; there is only do or don't do."
=====================
ngw quotes anim-cheers1 - \ "I will strip the beast" \ "the swingarm is just a hunk of metal" \ "gonna maybe ...dunno yet" \ "It's never done, thats the fun." \ "something about this site brings me back"
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#9

Post by Track T 2411 »

action1 action1 action1
"I have no special talent. I am only passionately curious." - Albert Einstein

"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.
Airshow
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#10

Post by Airshow »

The shocks are complete. 10oz of ATF and 20lbs pressure with a two day leak down test shows all is good.
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#11

Post by Airshow »

I used the fork lowers to "set" the shock seals.
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#12

Post by 82aspy »

you have the steel sleeves/bushings inserts that go in the end rubbers?

Image
"there is a Darwinian element"
Yoda said, "There is no try or not try; there is only do or don't do."
=====================
ngw quotes anim-cheers1 - \ "I will strip the beast" \ "the swingarm is just a hunk of metal" \ "gonna maybe ...dunno yet" \ "It's never done, thats the fun." \ "something about this site brings me back"
Airshow
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#13

Post by Airshow »

Yes sir. Bagged and tagged for final assembly on the bike.
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jdvorchak
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#14

Post by jdvorchak »

Really nice job and looks like great results! Congrats!
New users please visit our "Shop Talk" for common tips and help:
http://ngwclub.com/forum/page/ST


Don't fix it 'til it's broke...
The person with the most toys wins!
If it has wheels or a skirt you can't afford it.
Amateur Radio Station WW9L

71 CL350 with Bingham side car
2021 HD Triglide
2008 HD Dyna Low Rider
83 KZ1100L1 Son totaled it
83 KZ550LTD Shaft sold

Previous bikes: 84 GL1200 STD, 83 KZ550LTD, 83 CB1000, 78 CB400A, 82 CB900F, 79 CB750K, 2001 GL1800, 2000 Dyna Super Glide, 1972 CB350 K4, 1985 GL1200A, 1997 1200 Sportster, 84 GL1200I, 82 Honda CM400E, 81 Suzuki GS650L, 72 Triumph Bonneville 750, 72 Honda CB350, 66(?) Honda 305 Scrambler, 6? Yamaha yz250, 62 650 Matchless (Norton-Villers).
John
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jdvorchak
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Re: 1980 GL1100 air shock rebuild. New springs. Need guidanc

#15

Post by jdvorchak »

Just curious are those new gators or the original? If new where did you get them and how much? If you don't mind me asking.
New users please visit our "Shop Talk" for common tips and help:
http://ngwclub.com/forum/page/ST


Don't fix it 'til it's broke...
The person with the most toys wins!
If it has wheels or a skirt you can't afford it.
Amateur Radio Station WW9L

71 CL350 with Bingham side car
2021 HD Triglide
2008 HD Dyna Low Rider
83 KZ1100L1 Son totaled it
83 KZ550LTD Shaft sold

Previous bikes: 84 GL1200 STD, 83 KZ550LTD, 83 CB1000, 78 CB400A, 82 CB900F, 79 CB750K, 2001 GL1800, 2000 Dyna Super Glide, 1972 CB350 K4, 1985 GL1200A, 1997 1200 Sportster, 84 GL1200I, 82 Honda CM400E, 81 Suzuki GS650L, 72 Triumph Bonneville 750, 72 Honda CB350, 66(?) Honda 305 Scrambler, 6? Yamaha yz250, 62 650 Matchless (Norton-Villers).
John
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