My Shock rebuild in pics

[sjsingle1]

its a 85 YZ250 shock desperately in need of some TLC....not every step in the process is documented ....but just an interesting pictorial of whats inside a shock

 

 

spring removed

[sjsingle1]

 

body apart

[sjsingle1]

 

everything on the shaft with a new bumper

 

new race tech seal head the inner bumper and stock valving on top

 

stock valve

 

no locktite....they used a spot weld to keep it in place

 

the new seal has more bushing area than OEM

 

inner bottom out bumper

[sjsingle1]

 

wish I had some assembly pics....but I did not do the assembly......Piper Performance in Decatur TX .....a local Race Tech Center did the deed and I was not around to see it get done

 

new race tech spring and gold valve...seal head ....bumper....and hose 

[sjsingle1]

 

the new RT spring was about 1/2 shorter than the stock spring so the pre load was adjusted by the circlip location on the shock body

[sjsingle1]

 

I cleaned out all the crap under the rebound adjusters rubber seals....nasty in there....greased it all up

[sjsingle1]

 

used some new alls balls shock bearings.............they fit a little looser than OEM in the bore......may go back to OEM.......getting those circlips out was a P I T A !!!!

[bergman501]

is this shock on a yz you just rebuilt ? is it going on a tt600?

[sjsingle1]

i am putting it in a 86 IT200......the IT has a 40mm shock and the yz is a 46mm....and the yz has that compression adjuster

[greg-15]

i am putting it in a 86 IT200......the IT has a 40mm shock and the yz is a 46mm....and the yz has that compression adjuster

Your valve stack is almost the same as the one in my 1982 Suzuki RM I just replace. Unique design, Guess it was a KYB design. The three shims open like an accordion when the stack bottoms out. Interesting.

[sjsingle1]

i was surprised at the stock ancient valving......the yammis use a Soqui shock.....which is a KYB clone.....the gold valve uses more shims in the stack......i have the shim numbers but did not get to see it......its not installed yet so i dont know how it handles yet

[sjsingle1]

and you will notice in the race tech seal head.....and also on  the stock seal head ( not pictured )....it does not have the rubber bumper built in like i see in current seal heads.......the seal head here hits up against the bottom of the piece that the valve rests on......if i had gotten a seal head with a built in bumper.......alls balls.....it would have been useless without the stock bumper

[sjsingle1]

my mistake....its a 84 shock ....not 85.......85 was the first yr for the BASS system and in 86 they change the shock out to a integrated reservoir like all shocks have now

[Zrt1200]

Will the 46mm shock and spring clear the Air box on the IT200 as there is next to no room with the stock shock??

[sjsingle1]

i assume it must as race tech only sells the  bigger 46mm spring for the IT and I have read that other are using the bigger spring on their ITs