Author Topic: Cushion lever service and new shock install klv1000 (DL1000)  (Read 217 times)

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Offline pichulec

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Yesterday I finally manged to find time to do the job. I found that one of my friend have garage and he was willing to help me. If I knew how difficult the job will be I would never do it myself.

Centrestand has to be removed in order to get to the front bolt of cushion lever. I order to release the spring I used heavy duty string and rear wheel. Rear wheel casting has a hole which I used for this. To install it back, same procedure.


Only straps are suitable for doing the job.  Rear wheel also has to be removed in order to get space when installing shock different than stock. Also without rear wheel it is easy to raise swingarm during shock installation. To unbolt dog bones nuts 17mm socket is required for the nut and 14mm ring spanner is the only thing that will work. It was not possible to unbolt this by using 2x socket. Ring spanner had to be supported on the frame so I could apply massive force to the socket on my side and unbolt it. Same procedure for other bolts in cushion lever. Removing the bearings from cushion lever was almost impossible (I don't have bearing press) . I ended up destroing them completely to be able to remove them. For pressing out the bearings I tried to use the vice + 2x socket (size little smaller than bearing and other bigger to catch the coming out bearing) however it did not want to move at all, even after heating up the cushion lever. I ended up hammering out old ones. After cleaning of the cushion lever I heated it by heat gun and pressed in new bearings using socket of size little smaller than the bearing. (I have not touched dog bone bearings as they were fine and taking them out was to much hassle without proper tools). By the way, bearing where the  bottom of the shock is mounted was completely disintegrated.


Shock installation was also a bit difficult, it went from the bottom but it had to be rotated few times to be able to put it in place. But this kind of problem will be only if you install shock with external reservoir which is piggyback like mine (Nitron R2 ADV). Top shock bushing had to be grinded a bit in order to fit it in place. With shock in place assembly of everything was quite straight forward but time consuming, obviously I greased all the exposed bearings and torqued all the nuts using torque wrench. By the way, putting rear wheel in was pain in the Donkey. Not enough hands 😂
KLV1000 - my pride and joy

Offline Rusty Nuts

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #1 on: October 18, 2020, 07:52:21 »
Well done for tackling it yourself. :fix:  Your reward will be the new ride and handling. Enjoy the difference.  :thumb:

Offline Brockett

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #2 on: October 18, 2020, 08:13:31 »
Yes, well done. I've tackled that job on other bikes and it always a pain in the XXXX
Look at the clock and the calendar.
It'll never be now again.
So just get out and do it.
As fast as you possibly can.
Because .........
Nothing travels faster than the speed of time.

Offline TLPower

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #3 on: October 18, 2020, 11:29:48 »
As others have said well done. You have learnt new skills and hopefully confident enough to tackle other "jobs". :thumb:
To be happy, I don't need private helicopters,a Florida house or a yacht. I'm fine with my motorcycle,a trip to a forest in Bavaria and some lunch money.

Walter Rohrl.

Offline UK_Vstrom650

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #4 on: October 18, 2020, 20:37:23 »
 :text-bravo:

That was going to be on my to do list... it might stay on it  lol

Offline Rusty Nuts

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #5 on: October 18, 2020, 20:44:35 »
Pressing bearings/bushes in/out can be a twat of a job. "Domestic" shed-sized vices don't always have enough beef to cope.

Offline Asmith61

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #6 on: October 18, 2020, 21:52:05 »
Great job  :clap: :clap:

Offline pichulec

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #7 on: October 19, 2020, 06:48:24 »
The vice I used had wooden clamps but it was massive. I sticked 2 metal plates between and it worked for me.
Few pictures below.
KLV1000 - my pride and joy

Offline endintears

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #8 on: October 19, 2020, 19:58:01 »
In common with most  I use my socket set(s) as a source of  "rings" to match the bearing and housing sizes but I then prefer to use a long nut and bolt passed through the middle and together with suitable washers fitted use that to pull the bearing into place.

Offline Mr Nick

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Re: Cushion lever service and new shock install klv1000 (DL1000)
« Reply #9 on: October 19, 2020, 20:40:24 »
Don't throw old bearing races away as they're ideal for pressing them out and in as well.
Seems pearl asbo orange is faster after all....

'Don't believe all the quotes in forum signatures' - Aristotle

Orange Bikes Matter!