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post #1 of 20 Old 05-20-2011, 09:19 PM Thread Starter
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Thumbs up Shock spring install

So I started the install on my rear shock spring I recently purchased. I went with the 7.4 kg spring from top gun. Heres the link for more info.
http://www.topgunmotorcycles.com/KLR...lrsprings.html
The spring ran me about $80 and $20 shipping. You can call up the number on the sight and speak with someone about which spring is best for you.

Here is mine shortly after unpackaging it.

Here is the beginning of the disassembly faze. Just used a block of 2x4 under the kick stand and a car jack under the skid plate to life the rear end off the ground. This would be easier if i had a flat jack, but since I don't this does just fine.

Next your going to have to remove the rear wheel.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."

Last edited by Tom Schmitz; 03-15-2012 at 04:59 PM.
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post #2 of 20 Old 05-20-2011, 09:24 PM Thread Starter
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Next the dog bones are going to have to be removed. As seen here.

Here are the vacated holes of where the links used to be.

Next the lower shock mount bolt will need to be removed. It is the center bolt from the previous photo.

There it is. All three bolts on the shock linkage are out at this time.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #3 of 20 Old 05-20-2011, 09:33 PM Thread Starter
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So next is one of 2 options. If your going to be removing the swingarm. Which I recommend as they often corrode up and get froze in there. Then that is your next step. Highly reccomend getting some pb blaster of your favorite form of penetrant lube. I am going to for go removing the swingarm for now since mine is stuck and i am short one hammer and the lube needed.

The black hose in front of the top shock mount bolt will be needed to be bent out of the way to access the bolt.

Now go ahead and remove the too shock mount bolt.

At this point the shock will slide rearward. Make sure it does not fall out and get damaged. If the swing arm is off the removal will be easier. If not just lift up on the swingarm a bit and use the other hand to slide the shock out.

You should be left the a vacated spot where the shock used to be at this point. If you were going to be just replacing the entire shock then nows the time. Just reverse the steps and your done. Since I am going to be switching out just the spring i still have some work to do.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #4 of 20 Old 05-20-2011, 09:42 PM Thread Starter
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Here is the grimy and dirty stock klr shock. This will be brought to work with me tomorrow and springs swapped there since i have the use of a shock spring compressor I am going to take advantage of it.

Here is the swingarm nut broken loose. I have used some cleaner to try and remove some of the grime left behind by chain lube and general crap picked up on the road. But unfortunately for me I have a seized shaft and since no stores are open I will have to wait till tomorrow to remove the swingarm and grease the shaft and bearings.

This thing is going to need some persuasion to be removed so I will wait till tomorrow and get the right stuff rather than risk breaking something. Will post more tomorrow on the spring swap and more on the swingarm removal as well. So until tomorrow folks.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #5 of 20 Old 05-21-2011, 12:27 PM Thread Starter
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So I got to work today and the spring install went way easier than anticipated. Took only about 20 mins.
So I'm lucky and had on hand an ohlins spring compressor.
First step is to set the shock up I'm the compressor so that the bottom is facing upwards.

Next start to compress the shock spring so that the collar is able to be removed.
You may need to use something to pry up on the collar.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #6 of 20 Old 05-21-2011, 12:32 PM Thread Starter
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Next slide the collar off of the bottom of the shock leaving the black plastic piece in place.

Next slide the black protector out.

Now the spring needs to be relaxed slowly so that it will slide up and off of the shock.

Now the shock and spring will be separated along with the collar and black sleeve.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #7 of 20 Old 05-21-2011, 12:39 PM Thread Starter
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Next get your new spring ready to be installed.

Slide the new spring on the shock and mount back in the compressor.

Now your going to compress the spring enough to be able to slide the black sleeve in place.
Once the sleeve is in place make sure you have enough room to get the collar slid back onto the shock.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #8 of 20 Old 05-21-2011, 12:47 PM Thread Starter
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Once the collar is in place where it needs to be the spring can be slowly relaxed so that it comes and rests back in it's place on the collar.

Once it is happy and in it's correct place just release all tension on the spring and remove it from the compressor. Don't make the mistake I did and not line up my mounting holes. This is not a fun or easy task once spring is already installed.

Once finished the shock should look like this. The mounting holes are aligned so the shock will mount up easy. Now it is ready to be put back in the bike. While the shock is out I tool some time to give it a good cleaning and also found it a convenient time to adjust my damping settings. When I get off work I will be heading home for the reinstallation of the shock and some anger management training on my swingarm pivot shaft. Got some penetrant lube and a bigger hammer. So hopefully all goes well and I will be riding tonight.


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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post #9 of 20 Old 05-21-2011, 12:58 PM
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Excellent writeup with photos here. I appreciate you going to the trouble of chronicling all this work and I'm sure a lot of others do, too.

Good luck with the swingarm project: will be looking forward to seeing how the rest of that went for you.

I'm going to do the same thing next Winter and this is a great resource you've provided.

Obviously, a spring compressor is needed. I was considering just sending my whole shock to Topgun and letting them do it, but after your writeup, I'll probably just try to find somebody in town who has a compressor and do it myself. My cousin's kid has an auto shop in town and he'd probably let me use his.

Thanks again. Great writeup; great photos.



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post #10 of 20 Old 05-21-2011, 01:14 PM Thread Starter
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It's no problem. I know you said you would like it put up here in one of the other threads so if I'm doing the project anyway might as well document it and help out others who possibly are looking into doing a spring swap. After doing it I would say a spring compressor is most definitely needed. The spring is under so much tension you stand a better chance of hurting yourself rather than completing the job. I know top gun does the install for free if you buy a spring through them. But that would require the bike being down for a couple weeks and a little bit extra money involved for shipping. If it's winter and you can part with the bike for that period of time then that's a good option. As its middle of summer right now and my Klr is my only mode of transportation that's not an option for me. Needs to only be a weekend project. Either way I'll get it done. I'll post more tonight...


"If you don't ride in the rain, you don't ride."
"Work to ride and ride to work."
"Accidents hurt - safety doesn't."
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