dissasembly of rear shock covers

[Muddy]

Just a quick re-cap on the Dream shocks which a couple of people were asking about.

Pretty much the same as the others except for one fortunate detail. As the Dream top mount has to be removed to extract the covers it means that once the damper retaining nut is removed, the seal can be replaced without further dismantling. As the damper rod is 9mm and the shock body 27.2mm internal diameter, the CB160 seal can be used. this is part number 91254-216-000. Physical dimensions 9 x 27.2 x 10 mm.


The seal just slides off, but if you are going to re-use the seal - don't forget to protect it from the sharp threads with some tape....


Dream - Damper Disasembled by graham.curtis, on Flickr

I think I've covered almost all variations now.......

G

G'day G-man

Found the problem!

My C72 Dream dampers have a 9x26.4x10 seal rather than the 9x27.2x10 seal. That is why the 9x27.2x10 seals were getting very tight to get back in. I've pulled them back out (they weren't all the way in, but were very tight to get out) and will re-use the originals as I can't see any of the correct size on ebay or the net. The original seals weren’t leaking on this set of shocks, but I have another set that are leaking - I'll have to see what size seals are in them.

I measured the damper body and it is also 26.4 mm inner diameter so I guess I could get the internals machined out a little more so that the 27.2 mm seals fit if needed.

Can I ask for a little more assistance if possible please? In the photo that you posted above, which way does the inner sleeve go into the shock body? On dis-assembly I didn't notice there is a small (approx 1mm dia) hole in one end of the sleeve. Do you know which way the end with that hole goes back into the body - is it as shown in your photo?

Also I was thinking of using Loctite to secure the retaining nut without doing some deformation to the damper sleeve (as per original). Do you think that will suffice? How did you retain yours on re-assembly?

Thanks for your help and advice.

[G-Man]

Muddy

I may have misled you on the seal size. I apologise if that is so. I'll check again. I had sonly stripped one Dream damper just to make a comparison with the others I was doing.

Yes the end with the little holes goes in first. I got mine mixed up but dismantled a fresh damper just to make sure. You did well to notice it.

I'm not sure if you can get the 26mm seals. I made up a bushing to take modern seals for the dampers that needed those.

Cheers

G

[Muddy]

G'day G-man

All will be OK - where there is a will, there is a way. The old seals can go back into this set and I'll check the seal size in the other set and come up with something - like you, even if it is an adapter or something like that.

Thanks for the tip with the inner tube re-assembly.

I'll let you know how I get on, but I'm not concerned - scratch the head a few times and something always drops out.

[Muddy]

G'day Guys

For those interested, the 9X26.4X10 seals are back listed on ebay again from Peter Rey in Thailand. Search for "9X26.4X10".

I've just ordered my 3 sets.

As G-man said this is easy and worth doing to replace leaky seals or to improve the rear damping a little with slightly heavier oil.

[G-Man]

Muddy

Good spot on the seals. I've just ordered some.

Surprising how many different seals those crazy guys used. I think they got a bit more production engineering expertise as time went on.

Missed your question on locking the retaining nut. Yes I used a drop of Loctite hydraulic thread sealant to lock mine. The CB dampers use some adhesive-lined heat shrink also.

Thanks

G

[G-Man]

Guys

Latest (and belated) instalment of my on-going shock restoration project.


Honda CL72 / 77 Scrambler finished shocks by graham.curtis, on Flickr

Left is all NOS CL77 parts with custom color top covers
Middle is reworked CL77 with Girling covers and springs as detailed earlier in this thread.
Right is early CL72 with genuine (restored) Honda top covers and Girling lowers.

G

[conbs]

WOW! That is some beautiful work, Graham.