1200 rear shock rebuild

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rcmatt007
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1200 rear shock rebuild

Post #1 by rcmatt007 » Wed Aug 16, 2006 3:36 pm

at first I thought I had a rear end seal leak... but it turned out to be the left rear shock... the saddle bags are off, but I still have to remove the mounting bars for the bags. the left boot is oil stained from the leak

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yes that is a gold colored wheel and a 145sr15 radial tire... this bike has a sidecar and the rear wheel is from EML
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
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rcmatt007
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Post #2 by rcmatt007 » Wed Aug 16, 2006 3:41 pm

as mentioned above, this bike has a sidecar (and I rarely drive it)... when I went to remove the rear shock, I noticed the swing arm jiggled back and forth--how long has this been happening, I do not know.

turns out the left bolt for the swing arm had loosened up... here it is with an allen wrench, and I removed the lock nut to tighten it in place
Image
Last edited by rcmatt007 on Wed Aug 16, 2006 4:44 pm, edited 1 time in total.
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
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rcmatt007
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Post #3 by rcmatt007 » Wed Aug 16, 2006 3:45 pm

once I removed the lower boot cover I could see into the seal area... there is a retaining ring (not circlip)... now how in the world to get this bugger out... tried a srewdriver, a nail, a box knife... finally it occured to me to tap the metal holding washer deeper down... once this was done, removing the ring was a snap (pun intended)
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
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rcmatt007
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Post #4 by rcmatt007 » Wed Aug 16, 2006 3:46 pm

the ring and retaining washer are out, now ready for the seal... no other clips or rings are there
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

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rcmatt007
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Post #5 by rcmatt007 » Wed Aug 16, 2006 3:48 pm

into the vice we go to blow the seal... btw a clean workplace is a sign of a messy mind (now where did I place that last tool?)
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

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rcmatt007
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Location: a foot on each side of the Red River

Post #6 by rcmatt007 » Wed Aug 16, 2006 3:50 pm

this is a really important step. wrap the shock with towels before you atempt to blow the seal out... I only put the bungee cord there to hold the towels, but it turned out to be a very wise decision
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

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rcmatt007
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Location: a foot on each side of the Red River

Post #7 by rcmatt007 » Wed Aug 16, 2006 3:52 pm

you will know when the seal is out -- POP! -- I used about 100# of air and a rubber tipped nozzle... this is how high the seal blew, fortunately it was all covered with towels held by a chord
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

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rcmatt007
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Location: a foot on each side of the Red River

Post #8 by rcmatt007 » Wed Aug 16, 2006 3:54 pm

parts are ordered, when they arrive I will post pictures of the rebuild
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
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Post #9 by octane » Thu Aug 17, 2006 3:12 am

Thanks Rodger!!!
Da' Supercharged Bulldog

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"A designer knows he has achieved perfection
not when there is nothing left to add
but when there is nothing left to take away"

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rcmatt007
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Post #10 by rcmatt007 » Tue Aug 22, 2006 12:33 pm

parts arrived from bike bandit... tomorrow afternoon is the time.... it seems, from the steve saunders group that betweeen 8-9oz is what I need
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

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rcmatt007
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Location: a foot on each side of the Red River

Post #11 by rcmatt007 » Thu Aug 24, 2006 8:34 am

here are all the parts lined up and ready for re-assembly.... using the on-line parts fisch I actually ordered parts 1, 2 &3... turns out all I needed was #3 which is the seal


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five little monkeis playing on the bed... the first one siad, "roll over, roll over"
Last edited by rcmatt007 on Thu Aug 24, 2006 8:39 am, edited 2 times in total.
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

User avatar
rcmatt007
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Location: a foot on each side of the Red River

Post #12 by rcmatt007 » Thu Aug 24, 2006 8:36 am

before I could pour the atf fluid in (the shock would be upside down) I needed to close off the air hose hole. I used electrical tape and wrapped it tightly several times... turned out it leaked just a little bit, but worked well enough
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

User avatar
rcmatt007
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Location: a foot on each side of the Red River

Post #13 by rcmatt007 » Thu Aug 24, 2006 8:43 am

pouring in the atf was pretty straight forward... I heard various amounts, but the consensus was between 8 and 9 ounces... I think I started with 9, but when you count spillage, as somewhere in between
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

User avatar
rcmatt007
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Posts: 26696
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Location: a foot on each side of the Red River

Post #14 by rcmatt007 » Thu Aug 24, 2006 8:44 am

the inner slider and washer are next... they fit realitvely tight and needed to be gently tapped in
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image

User avatar
rcmatt007
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Posts: 26696
Joined: Fri Oct 21, 2005 12:48 pm
My Album: http://www.ngwclub.com/gallery/v/wingmans/rcmatt007/
Location: a foot on each side of the Red River

Post #15 by rcmatt007 » Thu Aug 24, 2006 8:47 am

next the seal.... interestingly, the seal does not "seat" against any thing as you push it in.... the retaining washer "seats" it as the air tries to push it back out... the retaining washer is part #4 and it is held by the ring#5
I put a little atf on the surfaces to help them slide into place
Image
-Rodger-
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978,
76 Ltd "cookies bike" up and running,
79 project, finished,
'86 1200 (Beth's) with motorvation sidecar, (being repainted and apart)
05 HD Road king and 08 HD Heritage softail (Beth's). I guess you can say we have MBS
http://www.ngwclub.com/forum/viewtopic.php?f=30&t=35846
http://s199.photobucket.com/user/rcmatt ... ion?sort=2
Image Image Image


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