how I learned to build shocks and forks

hillbilly
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9079
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8/16/2006
Location
Afton, TN, USA
Edited Date/Time 3/7/2014 12:52pm
In 1985 ktm watercooled their 500. I went to ride for kingsport and Mike eads a great man,he died in the 90,s hit a dumptruck withno lights.

Ktm recalled the shock shaft and mike was gonna replace it.

I still have it,was cracked almost in 2,happened to magoo,same year ,in euro.

Sam gammons ,owns muddy creek,worked there then.He was putting it together.

I watched,pissed him off and he left.I looked thru the book and saw the whitepower forks were like a shock,

Had a piston with shims and the shock was white power,hehe,white power!!

I knew it was the future,it wasnt a fork without air in the oil chamber like today but it was the best design.

After sam got air in the shock I ordered tools and shims.

When the shock was apart i saw how impossible it was to put together with the rebound setup it had.

The rebound shim stack had a cup washer that was preloaded to a nut with thread spring and turn counts.

Impossible,so I crossed reference the oil I was using to one I boughta 50 gal barrell of.

I put 5 gallon in a clean bucket and assembled the shock totally under the surfacen

No air bubbles,and had nitrogen to charge it.

Started valving ,would take it off 5 times a day and change it,same with forks.

My dad would come in and say i ws wearin the bolts out,I did,seriously.

But got it figured out,I won the 500ex on that bike at muddy creek long before it went ama.

It was a free for all,I recall the 1st,being to worried to look back I ran like the devil was chasing me.

I then went to Charlotte and won a state champ race on a bitching track next to a subdivision

Got arrested coming home for speeding,lol.

But,I learned how a shock falls off at 15 minutes or so and it you got stamina you setup stiff to start,

Then blow by them the last laps as the bike comes in.

That bike taught me so much, God the power it made.,they s pent the next 3 yrs detuning it for the masses.

Good tims,I still have the tools and seals for that bike,lol
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CnCRacing
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274
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7/6/2011
Location
Fairview, WV, USA
3/6/2014 4:02pm
Cool story.
hillbilly
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9079
Joined
8/16/2006
Location
Afton, TN, USA
3/7/2014 7:51am
I will add some more tonite,battery is dead in this asus pad i use.

I found out a lot about linkage rates and springs back then

In the 80,s muddy creek was 3 times,2 miles,the length today and ever year was loaded with black mulch

It whooped out like sand but was harder without the bike wander you get with sand.

So i tuned my suspension to save me if i landed short while jumping as many whoops i could.

I see that today in sx forks,you can't survive if a had gets blown off the bar in a hard landing
rcannon
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357
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2/11/2007
Location
West Jordan, UT, USA
3/7/2014 8:13am
Hillbilly, you know which parts of working on bikes I had the hate/love relationship with? I'll bet you did, too, and might the the motivation behind this story?

It was, for me, HAVING to rebuild a shock because you did not have the money to let someone else do it. I dont even recall being aware of a company who rebuilt them. No ebay used shock for me and my 1985 cr250. I really never wanted to learn how to rebuild a shock, I had to. Did you go through the same?

I remember how satisfying it felt when the shock was back together and working, but it was almost terror thinking you might have to save up 500.00 if you failed. At the time I was making 4.23 per hour (highest paid grocery bagger, thank you) and that money felt impossible.
alien
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125
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4/1/2008
Location
USA
3/7/2014 9:37am
OK Hillbilly is that when you started racing wearing the blue lifejacket ? If you fell into that 55 gallon barrel of oil you would just float back to the top. Saftey has no quiting time. Now to be serious there is nothing better than the ability to valve your own suspension, no shipping back and forth and no down time.

The Shop

Rooster
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4/1/2008
Location
Edmonton, CA
3/7/2014 9:43am
Wasn't that the same year MXA took the big 495 out to the salt flats and ran it well over 100 MPH?

Those big beasts were never that fast again.
3/7/2014 11:30am
Rooster...You mean like this one?
rallendude
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8/17/2006
Location
Adger, AL, USA
3/7/2014 11:37am
hillbilly - were you racing Cagivas in about '87-'88, maybe '89? Did you ever ride out of a box van?
3/7/2014 12:50pm Edited Date/Time 3/7/2014 12:51pm
Rooster wrote:
Wasn't that the same year MXA took the big 495 out to the salt flats and ran it well over 100 MPH? Those big beasts were...
Wasn't that the same year MXA took the big 495 out to the salt flats and ran it well over 100 MPH?

Those big beasts were never that fast again.
Not quite. That was an air cooled, piston port, twin shock 495 from 1981 that Dirt Bike mag supposedly hit 123.75 mph with. Think 125 like powerband in a big bore package!

1982 was a reed valved single shock (as pictured by AHRMA 361).


Cool story Hillbilly, btw.
Rooster
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Location
Edmonton, CA
3/7/2014 12:52pm
Thanks Matt, I knew it was from around that time, but those old mags got tossed long ago :-(

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