rear shock on 2001 kx 250

rclement48 · 02-24-2008, 05:53 PM

Can any one tell me how to rebuild a Rear shock on a 2001 kx250.

tigmaster · 02-24-2008, 06:11 PM

Well, you can do everything charge it with nitrogen but it kinda sucks. Start by removing the valve stem cover and gently discharging the shock. It is pressurized to about 140psi so be careful. After discharged, place a socket over the valve stem and hit it a few times gently until the bottom of the reservoir sinks in and a circlip is exposed. You will find a circlip which you need to compress and remove. Then the bottom of the reservoir will be able to be finessed out. It takes some effort but you can get it. You may need to pry a stop ring out with a screwdriver. Remove the spring tensioning nut and locknut and whatever keepers are there holding the spring in. You can then also clamp the shock up in a vise and remove the dampening adjuster usually just with an open end wrench. Drain the oil all the while. After the spring has been removed, you will see a small hole on the aluminum end from where the shock shaft exits. You can use the hole as a spot to put a punch or screwdriver and drive this cap off the end. In there, there will be another stop ring that has to be pried out. Yes I know it sucks but its the only way. You should already have your eyes on the oil seal. Once you have the stop ring pried out you will be able to pull the full assembly out. Now I know on Showa shocks there is an O-ring that you should replace while in there. Then with the assembly out, you will see an overly excessive amount of washers(valves) that will probably make you cry because of the sheer number. Anyways, you will need to remove the nut on the end of the shaft and pull everything off to get to the oil seal which goes on last. Wow, that is just the basics and I have no real secrets for making it easier. I will move this thread to another spot so our suspension expert can have a peak at it and see if he has any more info. And then as far as assembly goes, replace the bladder(the rubber boot) and when you put it on, make sure it is smooth and not sunken in or out. Sorry I can't help more but those are the basics.

rclement48 · 02-24-2008, 06:24 PM

thank that will get me going.

tigmaster · 02-24-2008, 06:29 PM

Ya, just don't rely on everything to be the same, I have a Showa shock and you have Kayaba.

rclement48 · 02-24-2008, 07:36 PM

Thank for your help. i got it apart. it was more or less the same. it is a pain thought.

tigmaster · 02-24-2008, 07:39 PM

That is good that everything is apart. Was there anything that was drastically different? Just wondering in so I know Kayaba specifics.

rclement48 · 02-24-2008, 07:40 PM

when I took the nut on the shaft of the top thred from the shaft came off with the nut. As long as i get the nut back on with out cross threding it will i be alright or will i need to get a new shaft?

tigmaster · 02-24-2008, 07:41 PM

This is very common. The nut was basically crimped on. Usually you are supposed to clean it up with a die.

rclement48 · 02-24-2008, 07:44 PM

thay were just about the same just not as many clips. and i had to depress the spring to get it off.

rclement48 · 02-24-2008, 07:45 PM

will i be alright as long as i get the nut back on with out crossthreding it?

02-24-2008, 05:53 PM	#1 (permalink)
rclement48 C Rider Join Date: Feb 2008 Posts: 13	rear shock on 2001 kx 250 Can any one tell me how to rebuild a Rear shock on a 2001 kx250.

02-24-2008, 06:11 PM	#2 (permalink)
tigmaster Administrator Join Date: Aug 2006 Location: Missouri, United States Posts: 6,510	Well, you can do everything charge it with nitrogen but it kinda sucks. Start by removing the valve stem cover and gently discharging the shock. It is pressurized to about 140psi so be careful. After discharged, place a socket over the valve stem and hit it a few times gently until the bottom of the reservoir sinks in and a circlip is exposed. You will find a circlip which you need to compress and remove. Then the bottom of the reservoir will be able to be finessed out. It takes some effort but you can get it. You may need to pry a stop ring out with a screwdriver. Remove the spring tensioning nut and locknut and whatever keepers are there holding the spring in. You can then also clamp the shock up in a vise and remove the dampening adjuster usually just with an open end wrench. Drain the oil all the while. After the spring has been removed, you will see a small hole on the aluminum end from where the shock shaft exits. You can use the hole as a spot to put a punch or screwdriver and drive this cap off the end. In there, there will be another stop ring that has to be pried out. Yes I know it sucks but its the only way. You should already have your eyes on the oil seal. Once you have the stop ring pried out you will be able to pull the full assembly out. Now I know on Showa shocks there is an O-ring that you should replace while in there. Then with the assembly out, you will see an overly excessive amount of washers(valves) that will probably make you cry because of the sheer number. Anyways, you will need to remove the nut on the end of the shaft and pull everything off to get to the oil seal which goes on last. Wow, that is just the basics and I have no real secrets for making it easier. I will move this thread to another spot so our suspension expert can have a peak at it and see if he has any more info. And then as far as assembly goes, replace the bladder(the rubber boot) and when you put it on, make sure it is smooth and not sunken in or out. Sorry I can't help more but those are the basics. __________________ --'03 CRF450r-- --FMF Pipe, Pro-Tech Revavle-- --Excessive Rebuild In Process-- --Now It Is The End, Probably...-- --'06 CBR F4I-- --Bone Stock-- Check Our Latest How-To Here

02-24-2008, 06:29 PM	#4 (permalink)
tigmaster Administrator Join Date: Aug 2006 Location: Missouri, United States Posts: 6,510	Ya, just don't rely on everything to be the same, I have a Showa shock and you have Kayaba. __________________ --'03 CRF450r-- --FMF Pipe, Pro-Tech Revavle-- --Excessive Rebuild In Process-- --Now It Is The End, Probably...-- --'06 CBR F4I-- --Bone Stock-- Check Our Latest How-To Here

02-24-2008, 07:39 PM	#6 (permalink)
tigmaster Administrator Join Date: Aug 2006 Location: Missouri, United States Posts: 6,510	That is good that everything is apart. Was there anything that was drastically different? Just wondering in so I know Kayaba specifics. __________________ --'03 CRF450r-- --FMF Pipe, Pro-Tech Revavle-- --Excessive Rebuild In Process-- --Now It Is The End, Probably...-- --'06 CBR F4I-- --Bone Stock-- Check Our Latest How-To Here

02-24-2008, 07:41 PM	#8 (permalink)
tigmaster Administrator Join Date: Aug 2006 Location: Missouri, United States Posts: 6,510	This is very common. The nut was basically crimped on. Usually you are supposed to clean it up with a die. __________________ --'03 CRF450r-- --FMF Pipe, Pro-Tech Revavle-- --Excessive Rebuild In Process-- --Now It Is The End, Probably...-- --'06 CBR F4I-- --Bone Stock-- Check Our Latest How-To Here

02-24-2008, 06:24 PM	#3 (permalink)
rclement48 C Rider Join Date: Feb 2008 Posts: 13	thank that will get me going.

02-24-2008, 07:36 PM	#5 (permalink)
rclement48 C Rider Join Date: Feb 2008 Posts: 13	Thank for your help. i got it apart. it was more or less the same. it is a pain thought.

02-24-2008, 07:40 PM	#7 (permalink)
rclement48 C Rider Join Date: Feb 2008 Posts: 13	when I took the nut on the shaft of the top thred from the shaft came off with the nut. As long as i get the nut back on with out cross threding it will i be alright or will i need to get a new shaft?

02-24-2008, 07:44 PM	#9 (permalink)
rclement48 C Rider Join Date: Feb 2008 Posts: 13	thay were just about the same just not as many clips. and i had to depress the spring to get it off.

02-24-2008, 07:45 PM	#10 (permalink)
rclement48 C Rider Join Date: Feb 2008 Posts: 13	will i be alright as long as i get the nut back on with out crossthreding it?

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode

LinkBacks (?) LinkBack to this Thread: http://www.mototips.com/trs-thompson-racing-suspension/11907-rear-shock-2001-kx-250-a.html
Posted By	For	Type	Date
Technorati: Discussion about “rear shock on 2001 kx 250”	This thread	Refback	03-10-2008 05:00 PM

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Dirt Bike Pit Bike Super Pocket Shock - Rear Adjustable	Mototips	Items for sale on ebay	0	02-11-2008 11:04 PM
Fastace 10.5" Adj Rear Shock Pit Dirt Bike 125cc XR SDG	Mototips	Items for sale on ebay	0	09-28-2007 11:25 AM
1000 Lb REAR AIR SHOCK HONDA XR 50 CRF 50 ATV Dirt Bike	Mototips	Items for sale on ebay	0	09-24-2007 11:32 AM
NEW REAR MONO SHOCK Spring for 125cc Off Road Dirt Bike	Mototips	Items for sale on ebay	0	08-27-2007 12:23 PM
1989 kx 80 Rear Shock assembly motocross dirtbike	Mototips	Items for sale on ebay	0	05-25-2007 06:03 AM

Remove advertisements Sponsored links