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Rear shock rebuild by myself
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In a winter time while my bike was sleeping I decided to fix a rear shock. Sometimes fixing can make things worse. But this time I succeeded. The shock was leaking the oil a little bit. I didn't want to repair a bike in summer during offroad season nor buy OEM shock or aftermarket cause they are to expensive. Yamaha come on... push the prices down :)

I like making photos as it keeps the history :) Adding lots of pictures.

Not much text here.

Ok, I will add a few words. Plase ask question if any. Basically I bought some OEM parts (seals, bearing) from partspack.com. It was cheaper than partzilla.com. The main seal RACE TECH SSSH 4614 Shock Seal Head 46x14x20  I bought on ebay. eBay user trukb3 sold me. I think it was the last one. You may ask him if he has more. The rubber seal you can buy from Chinese too aliexpress. p.s. is it a simplest way to add URL instead of going to HTML Editor and doing the work maually?

Chinese seal is twice cheaper than entire seal (rubber and metal) . We all know what the quality Chinese produce. So, this is your choice. In the images you will see that Race Tech seal is almost the same dimension as OEM old.

So, I completely removed my shock and dismantled by parts. Observe that the main axle is not rusty and still has chrome on it. If it is not oil may still leak after rebuild. In my case there were a few dots rusty in the bottom. However, this area was not critical, i.e. the seal could not reach this area, spring and shock rebate gasket won't let it go down and reach this area.

The aluminium "flask" had some wear, but it was not critical too. I disambled my wife's brother TTR shock too. The condition of flask was almost identical. I left the top original bearing of the shock. As it was in very good condition. I can sell the new bearing if someone is interesting.  I replaced seals of the bearings and put new metal covers. It took me some time to remove these metal covers. I used hemmer and flat screw drive.

I installed the air valve that I took from bicycle inner tube. For this I bought the tap to make a new inner thread on the cap of extension tank. I don't remember the thread size but I can figure it out. 

So, I changed the main seal and assembled all parts together and filled with shock oil 2.5. And was pumping the piston to get rid of air bubbles. I don't remember how much oil I put. 

In the air/oil tank I blow the air using simple bicycle pump. I didn't use nitrogen gas.

So far so good shock works, It reacts on soft/hard settings and rebound adjustment.  

Mine main resource on how to rebuild shock was this site http://greywolf.ru/index.php?option=com_content&task=view&id=51&Itemid=242 and here http://greywolf.ru/index.php?option=com_kunena&Itemid=270&id=251&catid=17&view=topic



-- Edited by honda15i on Tuesday 8th of March 2016 11:07:32 PM

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learning to ride on 1993 TTR 250

Ex 1997 and 1998 Honda XR 250



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Excellent post - very many thanks!

Brian



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Exeter, Devon, UK

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Great post, like the many pictures and hyperlinks.

Defo tempting installing the schraeder valve and using shock pump..

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Pete. South Somerset, England.



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Sharing a video on rear shock rebuild from our russian friends:

https://youtu.be/YnsJjErdgRk

 

oil seal from all balls 37-1116



-- Edited by honda15i on Monday 27th of April 2020 12:03:37 PM

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learning to ride on 1993 TTR 250

Ex 1997 and 1998 Honda XR 250

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