Author Topic: Original Koni shocks rebuild.  (Read 2827 times)

Online Stevex

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Original Koni shocks rebuild.
« on: March 03, 2020, 11:06:52 AM »
My LM2 came with a pair of (original) Konis i.e. not Ikons.
I've read that they can be rebuilt and have seen photos of the rebuild procedure.
My Konis don't leak, are in good condition and having taken the springs off, the damping appears to be working ok when I pump the piston in and out.
I have no idea how old these shocks are and have been toying with the idea of rebuilding them for a while now...so to my question.
Has anyone rebuilt a their Konis and did it (particularly the re oiling) make any difference to their operation?
Having converted my forks to cartridge internals, I'm wondering whether the Konis could use a re vamp, but they are old hat by today's standards.
« Last Edit: March 03, 2020, 11:11:08 AM by Stevex »

Online Tom H

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Re: Original Koni shocks rebuild.
« Reply #1 on: March 03, 2020, 11:19:12 AM »
Unless someone has done them, your oil is probably black.

They are not hard to do, except getting the gland nut off. I modified a tool to do the job. I don't remember the screw size, find one that fits tight and make sure that the tool sits flush with the nut when the screws are fully in.


   


Tom
2004 Cali EV Touring
1972 Eldo
1970 Ambo V1000
1973 R75/5 SWB with Toaster
1973 R75/5 LWB
2007 HD Street Bob
1953 Triumph 6T (one day it will be on the road!)

Offline wirespokes

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Re: Original Koni shocks rebuild.
« Reply #2 on: March 03, 2020, 12:08:20 PM »
I got a tool like this to work on my Konis. Seemed like it was cheaper than that, though. I recall making a different size pin to fit the gland nut.

I made a spring compressor from 2x4 bits and all-thread. Carved out indents for the spring coils. The gland nuts are pretty tight and might require heat in addition to penetrating oil.

Probably a good idea going in there and servicing the shocks - if nothing else it'll help them live a longer life.

https://www.ebay.com/itm/Small-Face-Pin-Spanner-Wrench-1-2-drive-Gland-Packing-Nut-Adjustable-Tool/362619372227?hash=item546dcc82c3:g:GgcAAOSwd4tT7VM1


Online PeteS

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Re: Original Koni shocks rebuild.
« Reply #3 on: March 03, 2020, 12:13:11 PM »
I rebuilt mine (7610s) many years ago. I made a tool using dowel pins. Its not that hard to do.

Pete

Offline huub

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Re: Original Koni shocks rebuild.
« Reply #4 on: March 03, 2020, 02:51:46 PM »
they are 50 year old technology, so dont expect too much.
the valves on these tend to clog up due to sarf coming from the seal, so a good cleaning and new oil is probably a good idea

Online Tom H

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Re: Original Koni shocks rebuild.
« Reply #5 on: March 03, 2020, 03:04:45 PM »
This is what I made the spanner from:

https://www.harborfreight.com/adjustable-pin-wrench-36554.html

Drill out the original pins. Find 2 bolts that fit snugly into the holes in the nut. Tap the holes in the wrench to fit your bolts. Then look at my pictures above to put it together.

When you use it, make sure that the tool is flush against the nut and the pins are in as deep as you can get them without lifting the tool off the nut. The handle is too short for leverage, so I found a length of pipe to slip over and extend the handle.

Tom
2004 Cali EV Touring
1972 Eldo
1970 Ambo V1000
1973 R75/5 SWB with Toaster
1973 R75/5 LWB
2007 HD Street Bob
1953 Triumph 6T (one day it will be on the road!)

Offline 93spada

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PJM

Online Stevex

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Re: Original Koni shocks rebuild.
« Reply #7 on: March 13, 2020, 04:33:32 AM »
So, I've been trying the remove the gland nut from the first shock now for a few days and it isn't budging. I bought a peg spanner and fitted some cut down bolts who's plain shanks fitted snugly into the nut holes and have been soaking the nut in WD40. Last thing I want to do is ruin the gland nut and I can't see any other way of getting the job done. I did use some mapp gas to heat up the area but that hasn't helped and for a while the ram seal started to pass oil. Since it's cooled down the seal is oil tight again and moving the ram in and out, the damping is smooth and effective. There is also a pronounced difference when rotating the damping rate selector, so the shock is actually in good working order. Pita.
« Last Edit: March 13, 2020, 04:34:08 AM by Stevex »

Offline brider

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Re: Original Koni shocks rebuild.
« Reply #8 on: March 13, 2020, 11:05:55 AM »
So, I've been trying the remove the gland nut from the first shock now for a few days and it isn't budging. ...so the shock is actually in good working order. Pita.

I just bought a used set of these shocks and may just attempt a rebuilt also. Please keep us/me (PM if nobody here seems interested) informed of your progress.

Myself, if my shocks stroked on the bench like yours, I would be tempted to just ride them and see how they performed. In my case, they will be mounted on a Cal II touring bike, so I really am not worried too much about sketchy rebound on a fast sweeper. I have broken many things that were not broken by tinker-it is, but if I could get those gland nuts broken free, I'd sure try it.
'85 Cal II Auto
'71 Ambo project
'02 GasGas EC300
'07 Norge
'05 KTM 950 Adventure
Wish'd I'd never sold:
'72 Red Eldo
'74 White Eldo LAPD
'77 Convert with DB bags
'06 Gas Gas EC300
'86 LM IV

Online Tom H

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Re: Original Koni shocks rebuild.
« Reply #9 on: March 13, 2020, 12:07:06 PM »
If you built the spanner like I showed, you also need a piece of pipe to give you more leverage. Also make dead sure the bolts are bottomed out in the nut and the spanner is resting against the nut so it doesn't try to twist. Also look at which side I put the lock nuts on the bolts.

If you looked at the site mentioned, it has pictures and a description on how to take them apart. I did try my adjustable spanner like he used, not enough leverage to do the job and no way to easily add a pipe or the like for more leverage.

You do need to mount the shock in a vice to get the gland nut off. Remove the lower rubber mounting bushing and clamp that end in the vice with a rag or wood to keep it from getting scratched. If you try to just clamp it with the bushing in, the bushing gives and you can't get the torque needed to get the nut loose.

If my spanner doesn't work and your dead set on taking them apart, the next step is vice grips or a pipe wrench and a hammer. If you want to keep them pretty after using one of these, the nut can still be had. I think about $20-30 each.

Good luck,
Tom
2004 Cali EV Touring
1972 Eldo
1970 Ambo V1000
1973 R75/5 SWB with Toaster
1973 R75/5 LWB
2007 HD Street Bob
1953 Triumph 6T (one day it will be on the road!)

Online Stevex

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Re: Original Koni shocks rebuild.
« Reply #10 on: March 15, 2020, 09:26:17 AM »
Finally got the first shock apart, stopped using the peg spanner as it was elongating the holes.
Used some plumbers pliers which got it moving and actually didn't leave any marks I can't clean up easily.
Everything inside is remarkably clean, no seal degradation and the oil didn't look that bad.
Got a seal kit on order and will be putting them back together with softer springs.



« Last Edit: March 15, 2020, 09:27:27 AM by Stevex »

Offline 93spada

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Re: Original Koni shocks rebuild.
« Reply #11 on: March 15, 2020, 10:10:46 AM »




Don't know if this pic will set off the virus alert but...…
This is the Guzzi tool I made for the gland nut. Big and long.
The pins are from 2 cheap allen wrench sets
PJM


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