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My 1983 GL650i monoshock has failed in the collapsed or bottomed-out position. It holds air reliably and hasn't leaked any oil. I removed the exhaust system and all the linkages as well as the shock. I pressed or drove out all the pivot sleeves and cleaned and greased them and the bushings with a moly type grease.
I then tried to follow Sidecar Bob's directions regarding the shock. Using my 20 ton press I worked the shock through it's full travel multiple times, then inverted it and expelled 250 ml of oil and discarded it. Turning the shock upright, I worked it in the press to draw in 250 ml of mineral spirits. With this mixture I cycled the shock multiple times in the press and tried shaking it manually as well. I then used the press to pump out all the solution I could, which measured about 600 ml. I discarded all the old fluid. Turning it upright again I drew in about 600 ml of ATF. I followed Bob's directions to remove air from the fluid before reinstalling the shrader valve.
I was encouraged at this point as the shock responded well in the press. I reinstalled it in the bike and the rear suspension could be bounced again and I could put the bike on and off the centre stand again. With it collapsed it sat too low for me to be able to struggle it up. I put the exhaust system back on and everything else that had been removed. I put away my tools, tidied up and went for a ride. It was rather chilly and I only went 3 or 4 miles. Initially it rode great albeit a bit firm. I had charged it to 40 psi. Returning home I found the shock had again collapsed with no possible movement and I cannot again raise it onto the centre stand.
Has anyone else encountered similar problems and how did you resolve them? I have no choice other than to remove the shock again to replace or repair it. I've read reports of removing the main seal by cycling it in the press while full of oil or increasing air pressure to force the seal out. With the seal out I assume I can empty the oil more completely but is it possible to find and correct whatever is causing the shock to lock up. The spring is obviously fine as it functioned well in the press. I suspect the oil is restricted somewhere in the dampening passages. I think I found an aftermarket replacement shock made by Hagon which might be the simplest solution but not the cheapest. Has anyone experienced this issue and been able to repair the shock?
I then tried to follow Sidecar Bob's directions regarding the shock. Using my 20 ton press I worked the shock through it's full travel multiple times, then inverted it and expelled 250 ml of oil and discarded it. Turning the shock upright, I worked it in the press to draw in 250 ml of mineral spirits. With this mixture I cycled the shock multiple times in the press and tried shaking it manually as well. I then used the press to pump out all the solution I could, which measured about 600 ml. I discarded all the old fluid. Turning it upright again I drew in about 600 ml of ATF. I followed Bob's directions to remove air from the fluid before reinstalling the shrader valve.
I was encouraged at this point as the shock responded well in the press. I reinstalled it in the bike and the rear suspension could be bounced again and I could put the bike on and off the centre stand again. With it collapsed it sat too low for me to be able to struggle it up. I put the exhaust system back on and everything else that had been removed. I put away my tools, tidied up and went for a ride. It was rather chilly and I only went 3 or 4 miles. Initially it rode great albeit a bit firm. I had charged it to 40 psi. Returning home I found the shock had again collapsed with no possible movement and I cannot again raise it onto the centre stand.
Has anyone else encountered similar problems and how did you resolve them? I have no choice other than to remove the shock again to replace or repair it. I've read reports of removing the main seal by cycling it in the press while full of oil or increasing air pressure to force the seal out. With the seal out I assume I can empty the oil more completely but is it possible to find and correct whatever is causing the shock to lock up. The spring is obviously fine as it functioned well in the press. I suspect the oil is restricted somewhere in the dampening passages. I think I found an aftermarket replacement shock made by Hagon which might be the simplest solution but not the cheapest. Has anyone experienced this issue and been able to repair the shock?
