Rear Shock Rebuild time?

[rtbmrgl]

hello,
I have a 01 KDX200, was wondering if it's rebuild shock time.
The compression and damping adjustment don't seem to change anything, maybe slightly but hardly noticeable.
It does have some rebound dampening, not familiar with the bike.
If rebuilding, what brand and where is good source for seals, bladder.
Any specials tools.

thanks

[KDXGarage]

How many hours since the last time the oil was changed?

KYB (Technical Touch is the USA distributor)

shaft nut
bottom bumper
seal head
bladder
piston band
piston o-ring

Do you have the Kawasaki service manual?

[rtbmrgl]

Thanks for getting back so quickly.

I bought the bike used, I suspect the oil was never replaced.
I do have a service manual.
I will go over the manual before tear down, anything I need to look out for?

[KDXGarage]

The symptoms you described sounds like the oil is old and worn out. I used to work on KDX suspension around 2005 on here. A few people that had me work on their shocks said it felt so much better afterwards. I just did a normal oil chance and recharge without a revalve. They said they could tell a difference on the clicker changes.

Watch the Race Tech shock videos on Youtube. They made a huge difference for me when going from reading a manual to actually seeing it done.

Kawasaki sells KYB oil in a bottle labelled Kawasaki. K2-C I think is what KYB calls it. 45024-0002

$18.31 at Partzilla.

I would suggest you read up and watch some videos to make sure this is something you want to tackle your self. Don't be afraid to know when to let some shop handle it.

[rtbmrgl]

I was hoping you would suggest try changing the oil.
I've watch the race tech video, and been reading the service manual. I'm a retired mechanic so I don't have a problem diving into something I've never done before, just want to get my ducks in a row.
I rode the bike the first time today since fixing a bunch of stuff, the rear suspension didn't feel bad, I just notice fiddling with the adjustments didn't really change.
I'll try the oil change first like you suggested.

thanks again.

[kdxsully]

The tough part with doing it yourself is sourcing a nitrogen charge!

[KDXGarage]

The tough part with doing it yourself is sourcing a nitrogen charge!

I struggled for a while before I bought mine. (pic from 2005, some member's shock I was working on)

1991KDX200NitrogenFill.jpg (21.82 KiB) Viewed 4210 times

[kdxsully]

How much did you invest into that?

[rtbmrgl]

I’ll call around tomorrow to find a place to fill the nitrogen. KDXgarage, if I can’t find a place could I ship it to fill, I’ll cover shipping and your cost. I have a few sources that are in the racing business so they may help.

[KDXGarage]

kdxsully, $325 back then... Race Tech chuck, locally sourced parts otherwise

rtbmgl, I would rather not. Sorry. Hopefully, you can find someone who can charge it locally, as I assume you are in California.

[rtbmrgl]

kdxsully, $325 back then... Race Tech chuck, locally sourced parts otherwise

rtbmgl, I would rather not. Sorry. Hopefully, you can find someone who can charge it locally, as I assume you are in California.

No problem, just thought I'd ask. ,

[rtbmrgl]

Well I took the spring off and found a local guy that re-builds suspension. He hasn't disassembled the shock yet but noticed right away the shaft has some side to side play and said some oil is lost from either a leak or leaking bladder. So not sure how worn the shock housing is.
I'll get the damage report in a few days.

He only does suspension now.
https://www.rothracingmx.com/

[KDXGarage]

Cool. Let us know.

[rtbmrgl]

Hello,
These bikes are getting old and a lot of the shocks weren't maintained, case in point my KDX that I just bought, causing housings to wear out. If you buy a shock from say, eBay its a crap shoot of the condition. Are there any aftermarket shocks or maybe shocks from later bike that will work?. I thought Ohlins made one but, that was then, not now.

[javjacob]

I would have it fully rebuilt. I had both rear shocks on my 200 and 220 rebuilt and it was worth the cost. Once done you will know you are good.

[kdxsully]

I think what he’s saying is the body itself is worn out. I don’t really know what to say about that, because crapbay is just that - a gamble. Everyone on there just wants to sell their used junk bike parts.

[KDXGarage]

and every shopper wants NOS for three pennies

[kdxsully]

and every shopper wants NOS for three pennies

Including me

Wish I could get my hands on some of that stuff to sell.

[rtbmrgl]

.


Good news on my shock, the bore is not worn out. I guess I dodged a bullet, being low on oil can destroy the bore.

Don't have the numbers handy but he measured the shock bore and it was well withing specs.
Apparently the KDX pistons are not available but he found the same size that fits a 91-93 YZ250. He buys parts directly from KYB or US supplier, only 3 pistons left in the US.

(If I miss quoted anything I'll get the correct info when I pick up the shock.)

I've learned a really a good lesson on how important regularly servicing the shock. Another 20-years from now It will be even harder to restore these bikes.


.

[KDXGarage]

It is good that the bore is OK. What was wrong with the piston??