Koni shock rebuild

[Zombie Master]

I like that it has a choice pf pin sizes. I've got a good quality pin wrench, but that gland nut looks intimidating.

With these shocks, do you have to charge them with gas?

[Tom H Ca]

7610 series no, just oil.

The pin tool on fleabay looks like a nice one, but I don't think you'll have enough leverage with it for the shocks. In my link, I had to also use a piece of pipe to get more leverage. Even then it was tough.

Tom

[PAS]

The gland nut has 5mm holes and the upper nut has 3mm. You need strong tool grade steel pins or they will shear off. I couldn't get mine loose I had to send them to Koni just to break them free. They had a thread sealer and locker on them.

[Rob Frankham]

With these shocks, do you have to charge them with gas?

No...

Rob

[gspd]

I haven't personally rebuilt a shock in decades, I now send them to a specialist.
I don't remember the specific idiosyncrasies of the many different brands I've dealt with in a former life, but none were fun and easy.

I remember rebuilding some British bike shocks as a 'yute', and the only way to fill them was to assemble them while submerging them in a tub of hydraulic oil. Protective gloves, or actually protective anything, was strictly for pussies back then, so you can imagine the mess that was involved.

Oh, and one thing I do remember very clearly; The stench of old shock oil will permeate your skin, clothes and workspace and linger for ever.
It's like the worst fish oil you've ever smelled, with a whiff of burnt ATF and skunk, multiplied by 10.


Do yourself a favour and send them to a specialist, it's well worth it.

[Zombie Master]

I talked to my local mostly dirt bike dealer. He does shocks and thinks he has the tool. He suggested I pull a shock off and he would see if he can loosen the gland nut.

The only company I have found to rebuild these is in Pennsylvania. It could cost $500.CDN (Canadian) after the dust settles.
A rebuild kit would be around $50. These shocks are pretty basic. They only hold 80 mls of fluid.

[outerbanker]

What is the name of the company in P.A. ?

[Seth]

There is:

https://www.ikonsuspensionusa.com/contact/

[Zombie Master]

So I talked to Rodger at IKON USA. He was very knowledgeable and helpful. The cost to ship my shocks to and from PA along with the parts and labor, would be close to what new shocks would cost. So I asked him what parts he would typically replace and send me a list. I probably don't need all these parts, but they are 36 year old shocks. He also said the springs are probably good as the ones they provided were heavy duty for the BMW.

I need to find an exploded view of my Koni 7610 (1298) shocks

Rodger wrote:

"Yes, very nice to chat with you over the weekend and thanks for the pics.

Based on your request, if I had your shocks on the bench for service, I would fit the following parts:

Ikon/Koni #7610-1298 service parts (in USD):
1 x #SEAL7610 Seals and O rings kit to service 2 shocks $ 39.95
2 x 15.34.38.000.0 Bump stop, cone shaped, black rubber 25mm @ $ 9.95ea = $ 19.90
2 x 15.36.37.000.0 Rebound stop @ $ 2.95 ea = $ 5.90
4 x #003 Rubber / metal bush 12.1mm x 23.5mm @ $14.95 = $ 59.80
(assume you are re-using the metal reducer sleeves which slip inside bush - if not, they are $3.95 ea).
2 x 15.34.60.000.1 Bump plate white @ $ 1.55ea. = $3.10
2 x 15.23.24.017.1 Rubber dust boot @ $ 2.75 = $ 5.50
Total: $ 134.15 + $ 9.95 USPS insured shipping to Washington USA"

[SteveD]

So I talked to Rodger at IKON USA. He was very knowledgeable and helpful. The cost to ship my shocks to and from PA along with the parts and labor, would be close to what new shocks would cost. So I asked him what parts he would typically replace and send me a list. I probably don't need all these parts, but they are 36 year old shocks. He also said the springs are probably good as the ones they provided were heavy duty for the BMW.

I need to find an exploded view of my Koni 7610 (1298) shocks

Rodger wrote:

"Yes, very nice to chat with you over the weekend and thanks for the pics.

Based on your request, if I had your shocks on the bench for service, I would fit the following parts:

Ikon/Koni #7610-1298 service parts (in USD):
1 x #SEAL7610 Seals and O rings kit to service 2 shocks $ 39.95
2 x 15.34.38.000.0 Bump stop, cone shaped, black rubber 25mm @ $ 9.95ea = $ 19.90
2 x 15.36.37.000.0 Rebound stop @ $ 2.95 ea = $ 5.90
4 x #003 Rubber / metal bush 12.1mm x 23.5mm @ $14.95 = $ 59.80
(assume you are re-using the metal reducer sleeves which slip inside bush - if not, they are $3.95 ea).
2 x 15.34.60.000.1 Bump plate white @ $ 1.55ea. = $3.10
2 x 15.23.24.017.1 Rubber dust boot @ $ 2.75 = $ 5.50
Total: $ 134.15 + $ 9.95 USPS insured shipping to Washington USA"

https://www.ikonsuspension.com/specifications/