thander
Registered user
Hi to all,
it's been a long time since I asked for advice on my 1100GS (1998) but I am kind of stuck, hoping someone has been here and remembers the way out....
My rear shock started leaking and I thought I should repair it. Me and my mate have been fixing bikes for ages, we also have a fully equipped machine shop, so why not?
During the disassembly we destroyed the piston wear band so we had to replace it.
piston
Piston OD is 45.5 mm, shock body ID is 46 mm.
Looking around for a new wear band I found that all available for 46 mm shocks were 1.2 mm thick! Too much it seemed.
Talked to the supplier, he said "this is is correct, the KYB piston I have in front of me is also 45.5 mm and it fits". It seems that I need a set of tools.
So, I made a tool to fit the band over the piston for starters:
installing band on piston
There is a taper there in order to guide the band on the piston. It came out nicely:
band on piston
Next, the idea is to have a second tool with an tapered bore, that would 'size' the band to 46.3 mm. And so I did:
piston with band in sizing tool
I was a bit torn from all the squeezing:
small tear after sizing
And I could measure it at 46.3 mm.
Problem is that it was way too tight to get it in the bore, we even tried to hit it with a soft mallet, only to totally tear it to pieces:
installation gone bad
So, asking for the forum's wisdom.
Not sure what I did incorrectly, not sure how to improve the process...
Has anyone tried something similar before?
Thanks in advance.
BR,
Thanos
it's been a long time since I asked for advice on my 1100GS (1998) but I am kind of stuck, hoping someone has been here and remembers the way out....
My rear shock started leaking and I thought I should repair it. Me and my mate have been fixing bikes for ages, we also have a fully equipped machine shop, so why not?
During the disassembly we destroyed the piston wear band so we had to replace it.
piston
Piston OD is 45.5 mm, shock body ID is 46 mm.
Looking around for a new wear band I found that all available for 46 mm shocks were 1.2 mm thick! Too much it seemed.
Talked to the supplier, he said "this is is correct, the KYB piston I have in front of me is also 45.5 mm and it fits". It seems that I need a set of tools.
So, I made a tool to fit the band over the piston for starters:
installing band on piston
There is a taper there in order to guide the band on the piston. It came out nicely:
band on piston
Next, the idea is to have a second tool with an tapered bore, that would 'size' the band to 46.3 mm. And so I did:
piston with band in sizing tool
I was a bit torn from all the squeezing:
small tear after sizing
And I could measure it at 46.3 mm.
Problem is that it was way too tight to get it in the bore, we even tried to hit it with a soft mallet, only to totally tear it to pieces:
installation gone bad
So, asking for the forum's wisdom.
Not sure what I did incorrectly, not sure how to improve the process...
Has anyone tried something similar before?
Thanks in advance.
BR,
Thanos
