Koni Shock Rebuild

[Chakka]

I need to rebuild a set of Koni's. Does anyone have a copy of the rebuild instructions that are on the Penton Restoration Yahoo Site? They are too small to read and I had no luck printing them in a larger size.
Thanks in advance
Chris

[tofriedel]

Chris,

I had the same problem, so I retyped the info as best as I could make out.    See below.

Tony

KONI SHOCK ABSORBER SEAL REBUILD KIT
3361 Installation Instructions

1.   Grip the shock absorber in a vise by the lower mounting eye.
2.   Rotate the lower spring support to its lowest position.  Remove the spring by compressing it and remove the spring retaining clip.
3.   Grip the shock in a vise by the upper mounting eye.  Loosen the lock nut.  Remove the upper mounting eye, the lock nut, the flat washer and the rubber bumper from the shaft of the shock absorber.
4.   Grip the shock absorber in a vise by the lower mounting eye. Remove the threaded cap (use wrench 7303 or equivalent).  These caps are difficult to remove. In some cases due to paint in the threads and over tightening with an impact tool.  Throw the cap away.  
     Some helpful hints:
a.   Be sure the pins on the wrench are fully engaged in the holes.  Tap them in with a hammer, if necessary.
b.   Apply torque smoothly with downward load on the wrench to keep the pins from slipping out of the holes.
c.   If this does not work, put the wrench in position, extend the shaft to full length and slip a short section of pipe or tubing over the shaft so that it rests on top of the wrench.  The pipe or tubing should be long enough to reach one half of the threaded area at the end of the extended shaft.  Slip the flat washer on to the shaft and screw the upper eye back on and snug it down.  This will help hold the wrench in the holes while turning the wrench.
d.   In case you are still having trouble, grip the shock absorber firmly and use a punch and hammer in an impact tool to rotate the cap.  This will destroy the cap, but you are supposed to throw it away anyway.
5.   Remove the old shaft seal, the cupped retaining washer and the retaining spring and by sliding them off the shaft.  Throw this stuff away also.
6.   Pry the O-ring out of the shock absorber body using a slender pick or other tool.  Throw the O-ring away.
7.   Lift the shaft assembly out of the body.  WATCH CLOSELY THE ORDER IN WHICH THE PARTS COME OUT!!!  LAY THEM ON THE BENCH IN THE PROPER SEQUENCE!!!
8.   Drain the oil from the body.  The inner cylinder and foot valve will probably fall out. If they haven't already.
9.   Wash all of the metal parts, including the shock body, in solvent.
10.   Replace the foot valve, brass spacer (on newer units) and the inner cylinder.  Be sure the spacers are tight and held in place on the inner cylinder.
11.   Refill the shock with the proper amount and type of oil.  Pour the oil into the inner cylinder and let it overflow into the body cavity.  DO NOT OVERFILL!!!  USE ONLY SHOCK ASBORBER FLUID!!!
Standard Koni capacities are approximately"
11.9 inch  - - 62cc
12.4 inch - -  66cc
12.9 inch - - 70cc
13.4 inch - - 74cc
12. Install the shaft assembly into the inner cylinder (piston first).  Seat a new
      O-ring from the kit in the groove.  Be careful not to nick or cut it.
13. Tape the threads on the end of the shaft to protect the new seal.  Set the seal in the new cap and slide onto the shaft using a rotating motion.  Use a wrench to tighten the cap.
14. Adjust the shock to your preferences (according to the factory instructions).
15. Replace the rubber bumper, the flat washer, the lock nut and the upper mounting eye by tightening the lock nut.
     NOTE:  Your new cap sticks up a little higher than the original cap due to the addition of the wrench flats.  To restore full travel to the shock absorber cut approximately 3/8 inch off of the rubber bumper.
16. Do all of the above to the other shock and you're ready to go.

[Chakka]

WOW! Thanks Tony!! That's the ticket

Chris