Author Topic: Re building old koni 76f 1296 shocks (Read 7656 times)

rosewood · « **Reply #25 on:** July 23, 2018, 02:59:33 pm »

Sand blasted the outer tubes and springs..

Etched primed and painted gloss black as well as clear coat..

rosewood · « **Reply #26 on:** July 23, 2018, 03:05:51 pm »

Made a shaft clamp to hold the piston and held the rod in a milling tool holder and jig..I had to grind a 11mm socket down to undo the bolt in the end of the shaft first, used an impact driver ..

Removed the piston and layed out all the parts..

cleaned and made sure the piston orifices were all clear..

rosewood · « **Reply #27 on:** July 23, 2018, 03:32:12 pm »

Bottom valve, was very hesitant tackling this as I didn't want to break anything, a bit of pb blaster and with my modified 7mm socket and screwdriver it came apart easily..

The first pick shows the valve plates/washers etc. they are held down with swaged tabs on the bush, no way I was going to touch them..

Cleaned everything the best I could making sure all the small orifices were clear..

when reinstalling the above I made sure the stack of washers/shims were snug and then backed off a tad so they could still be turned a little by hand before locking the screw with the small nut at the back. I am not sure how precise this needs to be and it would be hard to measure but someone else mentioned leaving 3 thousands of an inch clearance..I may come back and redo this later..

Second to last pic shows the modded tools I used and made..as well as the ultrasonic cleaner, and brake cleaner for cleaning everything. The small brass wire wheels on a dremel were great at cleaning off the light surface rusting that formed after sitting for a couple of days..I coated everything with 5w fork oils (painted on with a small brush) while reassembling everything.

Will post more when I get around to putting them fully together again..

Hope all these images help others out there..

rosewood..

flatlander · « **Reply #28 on:** July 24, 2018, 05:38:49 am »

great thread, rosewood!

rosewood · « **Reply #29 on:** August 12, 2018, 05:54:19 pm »

OK just finished putting these back together...

Used a drop of lock tight on the bottom bolt when reassembling.

Installed the lower washer first then placed in the inner tube with the bottom valve fitted.

Filled the inner tube with 50ml of 5w fork oil then 30ml in the main tube. Not 100% on the correct amount but this is what I've read somewhere.

Dropped in the piston and shaft assembly next.

rosewood · « **Reply #30 on:** August 12, 2018, 05:59:06 pm »

Had to press in the old seal on the top valve boss.

Then spring and gland nut.

I used some sealer on the nut thread. This stuff doesn't cure fully so should be able to disassemble if required.

rosewood · « **Reply #31 on:** August 12, 2018, 06:04:40 pm »

Gland nut tightened.

Then final reassembly.

Finished product...

I just need to sort out new top mount bush, considering casting my own out of urethane but will cross that bridge later.

Hope this is helpful to anyone.

rosewood

NobleHops · « **Reply #32 on:** August 12, 2018, 06:14:26 pm »

That bushing is probably something I can help you with. Just measure the OD of that top eye and remind me what bike these are going on, so we get the right-sized steel insert part.

Please email that info, nils@restocycle.com

Best,,

Nils

rosewood · « **Reply #33 on:** August 12, 2018, 06:27:13 pm »

Thanks Nils, I was planning on turning up my own steel inserts and then 3D printing a tool to cast the urethane around them..Ill see how far I get first as it should be quite straight forward. But if you advise against it let me know. Ill send you an email with measurements anyway.

thanks
rosewood

Quote from: NobleHops on August 12, 2018, 06:14:26 pm

That bushing is probably something I can help you with. Just measure the OD of that top eye and remind me what bike these are going on, so we get the right-sized steel insert part.

Please email that info, nils@restocycle.com

Best,,

Nils

rosewood · « **Reply #34 on:** September 23, 2018, 03:39:08 am »

Ok I found some time this week to get the upper mount/bush sorted. I decided to DIY my own from a 3d printed tool some casting urethane and a couple of turned up steel bushes..

The pictures tell the story but I made the outer diameter of the bush size for size with the shock mount. I scoured the inner surface of the mount with some course sand paper and 'glued' them in with some more urethane mixture..

I have know idea how long these will last but they seem legit for now..

rosewood

BomberMann650 · « **Reply #35 on:** September 23, 2018, 01:05:19 pm »

This is a great thread! Very nice work everyone.

Looking forward to servicing the konis found on a commando 850. Are there basic rebuild kits for sale or will it be a line by line parts order?

rosewood · « **Reply #36 on:** September 23, 2018, 01:57:52 pm »

Hey Bomber best to contact Ikon with your particular shock model and see what they can do for you...I don't think anything from this era is supported now but you never know...If the shafts are good and they are not leaking then thats a good start.

Quote from: BomberMann650 on September 23, 2018, 01:05:19 pm

This is a great thread! Very nice work everyone.

Looking forward to servicing the konis found on a commando 850. Are there basic rebuild kits for sale or will it be a line by line parts order?

SF · « **Reply #37 on:** September 30, 2018, 08:12:49 am »

Wow great work! That is so cool making those bushings. I have a set on a 550 parts I’m going to take a look at.

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rosewood · « **Reply #38 on:** September 30, 2018, 05:33:55 pm »

Thanks SF...

yeah the printed mold worked well.....watch this space...I plan to use the same technique to make some new bump stops..

rosewood..

Duke McDukiedook · « **Reply #39 on:** October 01, 2018, 01:37:24 pm »

Noice! Me likey! We need to sticky this somewhere for the Koni rebuilders out there!

rosewood · « **Reply #40 on:** October 02, 2018, 07:11:29 pm »

Bump stops sorted..For these I used a 3M dental impression product we use for prototyping.. I think its silicone based.

Will post a pic once they are installed..Also purchased some period correct vintage koni vinyl stickers l will apply and clear coat when they are apart again..

rosewood

SF · « **Reply #41 on:** October 03, 2018, 04:07:57 am »

Are you going to be selling these parts your making?

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rosewood · « **Reply #42 on:** October 03, 2018, 01:03:36 pm »

Hi SF I wasn't planning on selling these.....tbh the actual parts from ikon are not very expensive it was just the shipping to NZ that made them excessive especially as these may not even end up on my bike...having the resources to make my own easily was why I went down this path...

The bushes are a bit of work to turn up the inserts and then needed to be 'glued in' and I'm not sure of the longevity of the material yet so not prepared to make these for anyone..

If you would like some bump stops though send me a pm I don't mind molding a few more as they are easy to do..again I'm not sure of the longevity of them but they are much less of a risk. can do them in brown and also a blue/greenish color which are a harder grade than the yellow.

rosewood

Quote from: SF on October 03, 2018, 04:07:57 am

Are you going to be selling these parts your making?

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Bankerdanny · « **Reply #43 on:** October 03, 2018, 01:08:53 pm »

Those eye bushing are really slick looking. Well done.

rosewood · « **Reply #44 on:** October 10, 2018, 01:51:44 pm »

OK last post from me on this...

I got the new bump stops installed, applied the decals and mocked the shocks up on the project bike...really pleased with how they turned out..

rosewood

SF · « **Reply #45 on:** October 10, 2018, 02:13:25 pm »

They look better than new. Nice job

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jaytee-nz · « **Reply #46 on:** October 10, 2018, 02:38:30 pm »

Great work Rosewood. I think I sent you some 550 airbox parts some time ago - is this the same bike or have you moved on to another ?
JT (New Plymouth)

rosewood · « **Reply #47 on:** October 10, 2018, 03:05:20 pm »

Hi JT yes you did send the airbox parts, thank you again for that ....this is the same bike unfortunately lol (time flys...). back then I was completely new to bikes and was just trying to get it running....Came across a heap of problems with the engine/frame and it quickly evolved into a ground up rebuild...completely rebuilt engine etc..

I have been slowly working on it on and off for 3 years now...Good news is I just have a seat pan to mold this week and the frame should be at the powder coaters then it can start going back together.

I should really start a build thread..its kind of a cafe/restoration project like many but I have my own twist on a few details with some custom carbon parts...

If you are ever in akl drop me a line..

rosewood

Quote from: jaytee-nz on October 10, 2018, 02:38:30 pm

Great work Rosewood. I think I sent you some 550 airbox parts some time ago - is this the same bike or have you moved on to another ?
JT (New Plymouth)

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Author Topic: Re building old koni 76f 1296 shocks (Read 7656 times)