Topic: Koni shock rebuild woes

[eurban]

Hey all-
Well my NOS Koni shocks for the 750 are in danger of becoming paperweights.  I received them without springs and foolishly never did a careful check of their operation.  I have gone to the expense (actually a Christmas present from my Bro) of getting a set of new springs for them only to realize now that their action is faulty.  The adventure continued as I made myself a tool to open the PIA resevoir nut and found a bunch of goo mixed in with the oil inside.  Ikon Suspension in OZ (who the springs came from)has been very helpful in advising me on the rebuild.  Apparently, the goo is the leftover of the rebound stop inside the resevoir.  This is supposedly very common on 60's/70s Konis even on unused shocks.  Anyone else experience this? . . . Well today in the dissassembly process I cracked one shock's piston (screws onto the end of the chrome shaft and fits tightly to the inner resevoir wall. Koni North America cannot supply this part and I am checking with Ikon but I doubt it will be available. Can anyone out there save my Koni's from the trash pile with some spare parts?  Thanks

[eurban]

They are the alloy bodied special D shocks 76F series model 1296.  Thanks.

[mcpuffett]

have you tried terry in oz? he may be able to help    mick.

[eurban]

Yep I did "speak" with Terry via email. . no go.

[jsaab2748]

I bought the same exact shocks off e bay two years ago. They were NOS and exhibited the exact
same behaviour, a sort of "sticky" action. I opened mine and discovered some type of sticky goo that I figured was something that had dissolved for whatever reason. Haven't done anything with them since, considered rebuilding them. I used my OE springs with them at the time, and was disappointed to have to take them off the bike after only about 50 miles. For those few miles that they were installed though, I've never felt the bike handle better. I was able to accelarate into curves that would normally require letting off the throttle. I guess my point is, they are good shocks, hopefully you can obtain the right parts. Persevere, it'll be worth it. Good luck. jim

[eurban]

Jim- Thats interesting to know.  If I do come up with the necessary piston I would be happy to order up an extra set of rebound stops from Ikon which would probably be all you need if you wanted to rebuild.  The seals on my my "new" shocks seem fine.. . .Getting the top nut off and the delicate piston unthreaded from the shaft seems to be the hard part.  That and recreating the correct tension in the foot valve after you take it apart to get all the goo out.  Also let me know if you want to sell your gooped up ones.  I might be interested . . .Shoot me an email if so.

[eurban]

Can anyone out there help? . . . . My apologies for this shameless self interested topic bump up. . .

[Terry in Australia]

Hey Eric if you don't do any good you could always send me your buggared piston and I could try to machine you up a new one? Maybe a nice brass one, perhaps? Cheers, Terry.   (Seat of pants engineering)

[eurban]

Thanks Terry . . .Its a pretty complicated and delicate piece & looks pretty tough to make. . . . .Ikon still hasn't got back with me so hopefully they can find me one in their old parts pile.  Can't say enough how helpful they have been (via email)!

[Terry in Australia]

Thanks Terry . . .Its a pretty complicated and delicate piece & looks pretty tough to make. . . . .Ikon still hasn't got back with me so hopefully they can find me one in their old parts pile.  Can't say enough how helpful they have been (via email)!

Unusually helpfull Eric, normally they don't even bother to reply, ask Mike Rieck, I had to order some springs for him over the phone because they wouldn't reply to his emails. Anyway, best of luck mate, Cheers, Terry.