1 How to rebuild Koni shock? Thu Dec 09, 2021 8:20 pm
Snod Blatter
Life time member
This is a long shot, but does anyone here have a clue how to rebuild the old Koni 3014-1009 KBA-90279 for 8v K100s and K75s? I've been a silly boy and bought this. I've replaced the gland nut seal in some Dial-A-Rides previously and frankly it was pretty easy so I thought this would be fine. But this isn't a Dial-A-Ride at all and upon inspection it looks pretty difficult, and not just because it's charged with gas..
The most useful thread I've found is this one but he never got as far as removing the gland nut. The problem is that the nut is smooth with no holes in it, and also the sides are chamfered so no real way to get mold grips on it to twist it out (which is how I did it previously!).
Does it turn out? Do I bash it out like this? Not that there's any lip to drift against. But then there's nothing to turn against either..
Secondly, the rod in mine has no adjusting holes at the top to set the rebound damping:
Replacement rod maybe? It also spins around freely, no clicks or anything - any owners of one of these shocks able to tell me if it should click or hit a barrier after turning a few times? I find it very strange. It also comes up short in the end piece, leaving a ~2mm air gap above it when everything is tightened in place. It's just weird.
So, uhh, any pointers?
The most useful thread I've found is this one but he never got as far as removing the gland nut. The problem is that the nut is smooth with no holes in it, and also the sides are chamfered so no real way to get mold grips on it to twist it out (which is how I did it previously!).
Does it turn out? Do I bash it out like this? Not that there's any lip to drift against. But then there's nothing to turn against either..
Secondly, the rod in mine has no adjusting holes at the top to set the rebound damping:
Replacement rod maybe? It also spins around freely, no clicks or anything - any owners of one of these shocks able to tell me if it should click or hit a barrier after turning a few times? I find it very strange. It also comes up short in the end piece, leaving a ~2mm air gap above it when everything is tightened in place. It's just weird.
So, uhh, any pointers?
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1989 K100RS SE ABS 8v VIN: 0149214
Others: 1.5 x CBX250RS-E, '94 CB250, '95 TRX850, '16 Z250SL, '01 R1100GS