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Old 01-07-2015, 09:48 PM   #1
HuckIt OP
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1978 IT400 Shock Rebuild

So I've put off the final part of my IT 400 restore as long as I can - rear shock rebuild.

The good is that it is in pretty good shape, still felt OK (for a 36 yr old bike) prior to removal and had lots of pressure still in it.

I'm trying to get that main pneumatic portion open so I can see what needs to be replaced and I can't figure how it comes apart.

Anyone out there ever tear into one of these?

Here is the current state, feel free to edit the picture with a big arrow and text that says "loosen this" :)



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Old 01-08-2015, 01:35 AM   #2
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I don't know sadly, but will be watching this closely as my 78 yz250 has a shock that needs tended to... good luck!

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Old 01-08-2015, 07:21 AM   #3
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It looks like it should unthread at the right side seam in the lower picture. I have some PB Blaster soaking at that seam but I'd like to know for sure before I force it...:/
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Old 01-08-2015, 11:25 AM   #4
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isn't there a clip in here? wee small wire clip...



it's been a while since i rebuilt the one on my '77 IT... but there was a very small wire clip that was removed once depressing the diaphragm/seal/rubber thing under it, allowing the shock to come apart. don't remember anything needing to unscrew, but it was a '77 shock; possible that it's different from your '78 i suppose...
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Old 01-08-2015, 12:28 PM   #5
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[QUOTE=dhallilama;25883936]isn't there a clip in here? wee small wire clip...QUOTE]

I'll clean it up better and take another look tonight but I sure don't remember seeing one.

BTW - Thanks for the picture, the boobies added a nice touch
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Old 01-08-2015, 12:29 PM   #6
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Quote:
Originally Posted by dhallilama View Post
isn't there a clip in here? wee small wire clip...



it's been a while since i rebuilt the one on my '77 IT... but there was a very small wire clip that was removed once depressing the diaphragm/seal/rubber thing under it, allowing the shock to come apart. don't remember anything needing to unscrew, but it was a '77 shock; possible that it's different from your '78 i suppose...
From what I've heard you are correct. Sometimes there are even two??

It's tough to know because at least my 78 yz? 78 dt, 83 it, the parts diagram shows nothing deeper than a "damper assembly"
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Old 01-09-2015, 02:26 PM   #7
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Looked again last night and can't find any clips or rings....may have a go at trying to unscrew the end this weekend.
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Old 01-09-2015, 03:15 PM   #8
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Just double-checkin: you released the pressure in there right? Roughly 200psi in there I'm figurin'


Seems like you're right? That would probably be a cover for the seal head, so it should come off.
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Old 01-10-2015, 10:37 AM   #9
HuckIt OP
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1978 IT400 Shock Rebuild

Ok, finally got the dam thing apart....

So the part I wanted to unscrew is just a light press fit. After soaking the seam with the PB Blaster for a couple days I clamped it in the vice and with some moderate twisting and rocking back and forth it came off.



Under it is one of the two thing lock rings (?) that need to be removed. Remove the first and it will slide apart a few inches.



Then the second one came be removed.



I haven't been able to find any information on how much oil the shock takes, manual says 0....so I measured what I could. I would estimate 300 cc came out of the shock, guessing I spilled 50 cc at least. The oils is also really watery. Not sure what weight it takes but it seems around 5 wt. Also really dirty so glad I tore into it.





I hope this helps someone else in the future and if anyone has any information on oil quantity or weights I'd appreciate it.

Now time to get cleaned up and head to the Phoenix Supercross in time to see some practice! Go Dungey (a guy can hope...)

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Old 01-10-2015, 11:26 AM   #10
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Nice pics!

Same here, my manuals don't indicate any oil measurement, just N2 pressure. Hmm.
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Old 01-10-2015, 12:36 PM   #11
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You don't want any air in the shock body.Totally fill it with oil and as you slide everything back into place it will push out what isn't needed.Its tricky and messy unless you can find someplace to put a bleed screw.
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Old 01-10-2015, 02:43 PM   #12
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Awesome, thanks for the info. Have to order the seals and I'll make a final update after I have it all back together
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Old 02-05-2015, 01:44 PM   #13
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Originally Posted by HuckIt View Post
Awesome, thanks for the info. Have to order the seals and I'll make a final update after I have it all back together
how's it goin' over there? I'm trying to nut up and do my own shocks, I need your inspiration haha
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Old 02-06-2015, 08:27 AM   #14
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Kept meaning to update this thread.

I followed the advise above and completely filled the liquid portion of the shock. I used 15wt because I couldn't find any 20wt. Recharged with 255 psi and the shock felt worlds better. I really think having the new oil in there did the trick, as I mentioned the old stuff was about the consistency of water.

I would definitely tackle it again. No need for a spribg compressor either, I was able to push down on the spring and pull the retainer halves out. Good luck and let me know if you run into any issues.

-andy
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Old 02-06-2015, 03:06 PM   #15
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Quote:
Originally Posted by HuckIt View Post
Kept meaning to update this thread.

I followed the advise above and completely filled the liquid portion of the shock. I used 15wt because I couldn't find any 20wt. Recharged with 255 psi and the shock felt worlds better. I really think having the new oil in there did the trick, as I mentioned the old stuff was about the consistency of water.

I would definitely tackle it again. No need for a spribg compressor either, I was able to push down on the spring and pull the retainer halves out. Good luck and let me know if you run into any issues.

-andy
Glad it went smoothly for ya. Next week will probably when I undertake my IT175 shock. Thanks!
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