Author Topic: 89 rear shock rebuild (Read 3595 times)

Stuartwhite1989 · « **on:** October 03, 2013, 01:21:21 pm »

My 89 250r shock is very bouncy at the top of the shock with no damper on it unless you push the rear of the quad down quite far it then has some dampening. I want to rebuild my rear shock myself to save costs. I have a machine shop at my work and I have access to press's and other tools. Can anyone recommend the best way to do it and what parts do I need to do this, failing that what shock is better then the lt oem shock and will fit on with slight modification. I'm not sure if many people on here are from uk but I am and find it hard to find many quad parts here. Most are from America on eBay

Chuckie25 · « **Reply #1 on:** October 03, 2013, 02:08:17 pm »

I plan to do this for both my 87 and 88 rear shocks. I haven't had the time or money to give it a try yet. The worst part is the nitrogen fill at the end from my figuring.

Sparky · « **Reply #2 on:** October 03, 2013, 02:47:26 pm »

Go on YouTube and search it. I don't believe they are hard to rebuild. I use a guy up in MN he charges $35 for shocks with a reservoir. He changes the oil and seals. He can shorten them also.
I have two rear shocks up there right now. One is my stock 1986 and the other is a newer one.
If anyone wants his info let me know.

Stuartwhite1989 · « **Reply #3 on:** October 03, 2013, 11:12:02 pm »

I have been looking but can't find a lt250 shock video. I also can't find the parts to service the quad in uk

Stuartwhite1989 · « **Reply #4 on:** October 04, 2013, 11:01:09 pm »

I have been searching the net and can't find no help with this. Only thing I can find is a shock seal head kit. Is that all I need? Even then I have to import it to uk from America. Also I can't find what oil or how much goes into it, is it worth rebuilding the shock? If not whats a better upgrade from another quad to fit the 89 250r. Will the piggyback shocks foul on anything as the lt250 shock reservoir is seperate. Most shocks have then attached to the side.

Chuckie25 · « **Reply #5 on:** October 04, 2013, 11:03:51 pm »

On airfoolers.com there was a Swedish member who's building a zilla. He rebuilt his own shock. I believe he's a member here but can't remember his name...

Iceracer · « **Reply #6 on:** October 05, 2013, 05:32:24 am »

Shock rebuild is pretty simple. Bleed out all the nitrogen from the bladder. Remove the shock spring. Take some penetrating oil and spray the reservoir end cap and push it in a little ways until you see the spring retaining clip. Hose it good with. Compressed air and a brass soft bristle brush to clean any dirt. Remove the clip carefully so as you don't create any burrs. Now you have to remove the end cap. Lubricate it good and push in the shock shaft, this may pop the cap out. If not you can use a little compressed air to get it out. Turn the pressure way down or use a bike pump. Hold a rag over the end as it will want to launch out along with oil if you give it too much pressure .
With the ressie disassembled, move to the shock body, use a chisel carefully , to get the bottom out cap to loosen up its a press fit. With the cap removed use a clothes pin to hold it up out of the way. Clean this cavity good like you did with the ressie cap. Now the hard part, you need a piece of pipe about 2 inches long that will fit over the raised seal on the seal head. Cut a slot in the side and slip it over the shaft, remove the clothespin and push the shaft down to engage the pipe. Press on it to depress the seal head exposing the retaining clip. If it won't budge usually a tap or two with a soft face dead blow will dislodge it. Remove the clip carefully. I like to use dental picks for this. Once the clip is out re-lubricate and put shock spring back on, slowly tighten and draw the shaft and seal head out.

Once disassemble Clean everything pristinly. You have to grind or drill off a small amount of the shock shaft off to remove the retaining nut . Once off be careful to not lose any valving I use a zip tie to slide it on to then close it . The seal head will slide rite off but you need a bullet to replace the new one onto the shaft to not ding a seal. Now is a good time if you want better valving to replace the valve with a race tech gold valve or a stadium suspension systems valve and Ohlins style shim stack.

Stuartwhite1989 · « **Reply #7 on:** October 06, 2013, 01:58:40 am »

-->thank you soo much for your post. I will give this a go. When re assembling how much oil do I fill it with? Can you recommend where the get the valve? What is the best way to get the air out? Why is this not in the manual

Stuartwhite1989 · « **Reply #8 on:** October 06, 2013, 11:05:58 am »

I removed the shock and removed the gas and the oil came out with the gas so to me that means the bladder has gone. Where can I get a new bladder

James Dandy · « **Reply #9 on:** October 06, 2013, 11:22:06 am »

I have one. My bladder was good, and I had already ordered the bladder. It was on backorder, so I told my shop to go ahead and tear down the shock, if the bladder was good, to rebuild it and I'd just keep the bladder. PM me for pics. I can only text or email them. It's oem. BNIpackage. I had my shock done at G and R motorsports in Walton ky. The tech there used to be the man at Mototech in Latonia (near Covington) Ky. These guys are really good and reasonably priced. I'll sell u the bladder for whatever I paid plus shipping. Mine is for an 87 shock, but I'll call G n R to make sure it's the same PN.

BadMoonRacing500 · « **Reply #10 on:** October 06, 2013, 12:41:33 pm »

This is for a zilla, but should help you with questions and has pictures. the 2 shocks are very similer. http://www.suzukiquadracerhq.com/chassis-suspension/shock-service-rebuild-101-part-1/

Sparky · « **Reply #11 on:** October 06, 2013, 03:52:27 pm »

Very informative post!!

Stuartwhite1989 · « **Reply #12 on:** October 07, 2013, 01:59:15 am »

I read through it and ill defo do it myself. How much do you want fr your bladder James and will you post to uk?

Iceracer · « **Reply #13 on:** October 07, 2013, 05:45:33 am »

Oil is simple fill the shock body to the snap ring groove and allow the ressie to get @1" of fluid.
Refill the body and put the shaft assy in , ,have to cycle it slowly to get most of the air out then fill above the piston so the seal head touches oil before the bleed holes in the side are closed off. Shove the seal head in and replace the snap ring BE sure to seat the seal head on the snap ring. Before moving on. Fill the ressie so oil just bleeds out before the sealing surface meets the body. I usually compress the bladder a little so I can use air to seat it. Thers no good place to pull on it without damaging the Schrader valve. You can assemble in the ressi first and the shaft and body second, its a matter of preference no difference in the result.

Iceracer · « **Reply #14 on:** October 07, 2013, 05:46:11 am »

Race tech has all the parts for a rebuild.

James Dandy · « **Reply #15 on:** October 08, 2013, 04:38:17 pm »

Sure I'd sell it. The price tag on it is $34, I didn't realize your in the UK. I've never shipped anything overseas. You'd prolly find it alot cheaper near home. I have no idea what it'd cost to ship. If you can't find it, message me and I'll go to the post office and find out

Stuartwhite1989 · « **Reply #16 on:** October 10, 2013, 04:20:56 am »

I have been searching and its driving me crazy I can't find one. I know the bladder is same size 1985-92. Also same as lt450r 2006-2009

James Dandy · « **Reply #17 on:** October 10, 2013, 01:00:06 pm »

I gotcha buddy. We'll get the one I got across the big pond to you somehow. The shop I go thru had this thing back ordered for weeks. I just sent you another email. Hopefully you can see the pics this time. Anybody have any advice on getting me paid from stu to my paypall in USD$? I've never dealt overseas, but I'm glad to help a Qracer bro out.

Chuckie25 · « **Reply #18 on:** October 10, 2013, 01:28:04 pm »

Use google to find out what your USD amount is in over-the-way money, then the buyer sends that much, then Paypal converts it over to USD for you. A buddy in Canada sent me some canook money and I had to flip it over like that

James Dandy · « **Reply #19 on:** October 13, 2013, 03:15:55 pm »

10-4 thanks chuckie. Just sent stu the total in USD with shipping $43.45. I hate to charge him that much for a HD rubber, but I didn't mark it up. I actually marked it Down .50c! Here's a pic

Stuartwhite1989 · « **Reply #20 on:** October 13, 2013, 03:44:45 pm »

Thanks much appreciated. I sent you payment of 43.50 US dollar to make it a nice even number. As soon as I receive it I can put my shock back together

will soon be riding her again. My mate has just brought a lt250r as it came up on eBay and he loved the power of mine.

Chuckie25 · « **Reply #21 on:** October 13, 2013, 04:06:14 pm »

I Guess i gotta go pull my axle and shock off now lol
Cant wait to see the insides of this thing and see how easy it actually is

James Dandy · « **Reply #22 on:** October 13, 2013, 04:11:24 pm »

Take pics of the tear down-rebuild for us. I'd like to have the knowledge. Hey stu, make sure you email me your exact address. I'll mail it out in the morning. I'll send pics of the postage reciept

Stuartwhite1989 · « **Reply #23 on:** October 14, 2013, 12:06:57 am »

I already have the shock off and the resi is stripped but I will take pics when I do it all. It's the same as the link above in this thread tht was posted but will still take pics

GrkGuy · « **Reply #24 on:** October 14, 2013, 07:37:30 am »

is your bladder bad, maybe gas leaked out of shock and let oil in

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Author Topic: 89 rear shock rebuild (Read 3595 times)

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