800GS shock bolt design flaw?

[Snowy]

For those that keep saying they read about it but don't see any proof.

1 of 3 bent bolts. I have 2 spare bolts in the toolbox, but haven't looked at them since the Indy kits top and bottom. I also have the Ralley Moto brace, drilled out to fit the Indy kit sleeve. I slightly bent a bolt with just the Ralley Moto brace, but it wasn't too bad.

Primarily mine are due to max loads over crap fire trails. One with the standard shock, from memory, and 2 with the Ohlins.

The Ohlins definitely bends them easier, because it lacks a anti bottom out circuit. It just blows through the last of the travel and goes "crunch".

Revalve and 22kg/mm spring helped, but hasn't "cured" it.


The main problem is, that as soon as it handles going faster, you go faster and then go crunch again.

I've been staring at the shelf full of Showa MX shocks in my garage and day dreaming. I wonder....

[johngil]

The Elka shock was a big improvement for me.

[Gangplank]

Originally Posted by johngil

The Elka shock was a big improvement for me.

If anyone is interested in ordering an elka shock I'm thinking about it. I can get a group price if a few of us are interested. PM me if you are...

[OZZY-GS]

I got back from a big trip offroad fully loaded and thought it was time to check my shock bolt
The bloody thing was bent. (And i was using the Rally Moto shock brace)
I ordered my Indy kit and proceeded to put it all together. Pressed the original bush out and then inserted the new bearing from Indy. Only problem was the inner race from Indy would not go in the bearings once pressed in but fitted fine before.
Took the shock to an engineer friend of mine and we measured the hole that the bearing where to be inserted.
What we found really pissed me off. Instead of being round the hole was out by about .5 of a mm.
How the hell does this happen? it must have been like this ex factory as when I looked at the old rubber bush the inner race was not in the centre of the rubber.

Anyway we bored out the shock and re inserted the bearing from indy and everything works great and installed perfectly.(I also bored out the ralle moto brace and installed that with the Indy kit.)
The hole time this was happening i was send messages to Indy and he was trying to help and to work out what had gone wrong.

I can highly recommend the Indy fix purely based on the customer service and his faith in his own product.

Now i just need to go out and try and bend the new bolt

[Indy Unlimited]

I suspect that bending the stock bolt caused the thin walled stock shock upper mount to get out of round. I am willing to bet the 0.5 mm bulge was at the top or bottom. No one has bent a bolt with my Indy kit or damaged a stock or aftermarket shock. Over 500 kits sold worldwide to date.
For any serious off road riding the stock set up or aftermarket shocks all need beefed up mounts.

[Snowy]

I don't praise lightly...

...some of you, the hateful nasty ones, will probably say I just love to hate things. Shame on you.


But I digress...

....Indy's kit works.


That's it. It works. It does what he says.

now to some of you that don't mean much, in this fast new consumerism age.

But if you come from a background where a man's word is his bond, a handshake is a contract, and a friend defends you until death...then it speaks a whole different language.


It works.


'nuff said.


Keep up the good work Indy. Respect.

[davidpetersen]

OZZY-GS: the bolt that bent... was that the original BMW buttery-soft 10.5 grade bolt, or was it a hardened 12.9 grade bolt?

[OZZY-GS]

Originally Posted by davidpetersen

OZZY-GS: the bolt that bent... was that the original BMW buttery-soft 10.5 grade bolt, or was it a hardened 12.9 grade bolt?

It was only the original bolt.
I suspect that if I had the 12.9 grade bolt that may have hung in there longer.

[Snowy]

Originally Posted by OZZY-GS

It was only the original bolt.
I suspect that if I had the 12.9 grade bolt that may have hung in there longer.

The 12.9 does hang in there longer.

But not much longer, as it turns out.

[PatrickM]

ZOMG getting that bushing out of the stock shock is turning into an endeavor. I've tried three different times and all with the same results, nothing.

I picked up a 30mm socket and tried a 13/16 but basically bent two stacked washers and with a 3/8" bolt, slowly started bending it because of force. I tried some oil/lube to see if that would help and came back later w/ the same results. Someone stated "a ton of force" and I'm believing them.

What is the trick? The best answer I heard is to take the entire thing out to someone with a press.

1. Pay someone to pop/press it out
2. Drill out the rubber
3. Hack saw the center

I would prefer doing something I couldn't back out of, but it most certainly looks like taking the destructive route is it.

[Indy Unlimited]

I use a 1-13/16" deep socket ( measures 27 mm outside diameter ) and using a 32 mm deep socket to press into on my shop press. It takes only 5 minutes to press it out once you have the right 2 sockets and a buddy to help hold the shock. Auto shop with a press should be able to help you do it for $20. It is critical to use a 27mm - 27.8 mm cylindrical object to press out the stock rubber mounted bushing. The rubber puts up a good fight. My kit installs easy with a simple vice to push the 2 bearings in.

[petzi-baer]

Not a real surprise, but still pretty pricey.

http://www.touratech-usa.com/Store/3...els-Suspension

But they come with Stainless Steel Bushings – "While many aftermarket shocks use aluminum bushings where the shock mounts to the motorcycle, Touratech Suspension uses high-strength, non-corrosive stainless steel. This creates a strong and rigid connection which is important for loaded touring motorcycles. The stainless steel bushings protect against corrosion and seizing and offer low maintenance and longer life."

Petzi-bear

[Gangplank]

Originally Posted by petzi-baer

Not a real surprise, but still pretty pricey.

http://www.touratech-usa.com/Store/3...els-Suspension

But they come with Stainless Steel Bushings – "While many aftermarket shocks use aluminum bushings where the shock mounts to the motorcycle, Touratech Suspension uses high-strength, non-corrosive stainless steel. This creates a strong and rigid connection which is important for loaded touring motorcycles. The stainless steel bushings protect against corrosion and seizing and offer low maintenance and longer life."

Petzi-bear

One piece or two piece bushing? If it's 2 piece it won't solve the problem.

Wonder who is making these for them? Sure looks like an ohlins.... just saying.

[petzi-baer]

Originally Posted by Gangplank

One piece or two piece bushing? If it's 2 piece it won't solve the problem.

Wonder who is making these for them? Sure looks like an ohlins.... just saying.

New company called Tractive:
Most of them are former WP employees:
http://tractivesuspension.com/about_...uspension.html

Maybe someone on this forum is going to the iMS in Long Beach and could check them out for us.

Petzi-baer

[Phreaky Phil]

Originally Posted by Snowy

The 12.9 does hang in there longer.

But not much longer, as it turns out.

Hey Snowy, i'm surprised you havent taken to that shock mount with you welder and put another plate in on the other side of the shock. The old DR didnt bend shock bolts
Do use your 800 2up much ? offroad.