Cycle News is a weekly magazine that covers all aspects of motorcycling including Supercross, Motocross and MotoGP as well as new motorcycles
Issue link: https://magazine.cyclenews.com/i/125712
By Rod Breaker Workshop REBUILDING THE MAVRICK SHOCKS ~ w Z W ..J U > U 2,1 Pull down the spring and insen proper size open end wrench onto the lock nut (on this shock it was 17mml. With a bar of some type in the top eyelet, back off the lock nut and then umhread the top eyelet from the shaft. Remove the top eyelet, spring keeper and the spring. Also remove the lock nut as it will be used on the new shaft. 3.) With a small punch, peen out 'the metal where the factory staked it as a locking system. Be careful not to damage the threads any more than possible, you will have to thread this cap back into the body after the new unit is installed. When the North American Imports Company started bringing in the Mavrick rear shock absorber from Japan, it was met with great enthusiasm by the motorcycle clientele. It had one great advantage over any of the other shocks on the market in the fact that they were rebuildable. Of colJtse many of the other shocks were also rebuildable; the only hitch was in obtaining the parts with which to rebuild them. The company not only brought in the shocks, but brought in the rebuild kits in at the same time. Mavrick shocks have become a familiar sight wherever motorcycles gather, and they are al.so standard equipment on SO,,", models of Kawasaki. I have long recommended that if a person. is buying a set of these shocks, that he purchase a set of rebuild kits at the same time. That way, should he ever need to overhaul them, he would have the parts on hand. If you happen to have a set of these shocks and are contemplating rebuilding them but are a little afraid to tackle the job, here is a step by step 'how to do it' in pictures. The rebuild kit consists of a new dampener unit and seal, a new buffer rubber and, new top and bottom mounting rubbers. 4.) When I obtained these shocks, they hadn't received any of the special removal tools as yet. so I made one up out of some scrap metal and a couple of old roller bearings for pins. I just drilled the holes a few thousandths smaller than the pins on 1-1/16 centers and pressed the pins into them. A center hole was drilled to accept the shaft. 5,) The homemade tool is 51 ipped over the shaft and the pins drop into the slots. The cap is merely unscrewed. Retain this cap as it is to be used again. If too much resistance is met removing it, thread it back in and clean up the threads, Use care in removing the '0' ring as it also must be used again. If you do not have any specs on how much oil goes into the shocks, you should have a clean container handy to 1,} With the shock adjusted in the lightest position, use a screwdriver to pry down the rubber buffer to expose the lock I'ut at the top of the shaft. These operations are best performed with the shock mounted in a vice for stability. BUENA PAil' CYCLE •••••••••••••••••••••••••••••••• catch the oil in the shock so that you can measure it. The dampener unit may then be removed; this is the main component to be replaced. Remove it slowty to avoid spilling shock oil. ~TORCYClE PARTS & SERVICE .. Specializing in Varna' d, • Off Road Equipment. 7872 Orangethorpe Buena Park 1714) 522-1041 TACO TWA" tOO - Now, .,.....t. .... wh••1 p.rform., - $219.50. OtlMr ......... low .. $119.95. Kits ... efta ..... dutch, ch.i" 95. Sencl2Scfer _hu.., ' - 8.) Install the rubber snubber and the lock nut on the shaft, pUll the shaft up as high as it will go and install the spring and the small top •••••••••••••••••••••••••••••••i. • 1. '301>- .......- $' a division of A, V. Carnicello Inc, .. spring collar. Dampener tube should also now be removed, but use care here also 8S most of the shock oil will be retained in this tube. Empty the shock unit and clean the unit and tube thoroughly. After cleaning the units, refill them with In most eases, the longest ~ou'll hav4! to wait for e~ele elothingat Valerian's is two or three minutes. Our supply of Damer Motocross leathers is exceeded only by our supply of Torsten Hallman leathers, Which is exceeded only by our supply of Champion leathers. lIS. aIHJut our 81ft eertifle4des g.) With a wrench on the lock nut, the top eyelet section may be threaded on by hand. Take care that it is not threaded down too far as the shaft yvill protrude into the mounting eyelet as shown by the ballpoint pen. McKav's shock fluid, or similar (this shock held 50cc). A common baby bottle makes a very good measuring beaker. Insert the dampener tube into the base before pouring in the oil or the oil will overflow when the tube is inserted. new dampener unit supplied in the kit. Insert' it very slowly into the dampener tube and bottom it completely. 6,) Install the 7.) Install the thin '0' ring and then thread the lock ring down into the body and tighten well with the pin tool. Using a small punch, indent metal into the pin holes to act as a lock as the factory had done to keep this ring from coming adrift. 'AMAHA ! fONTANA Yamaha-Sach's- 9008 Sierra Ave. Hodaka-Maico- Fontana Calif ra~ - S~:~ - (714) 822-2252 (Continued on next page) ENDURO RIDERS Route sheet holders. mileage dial and magnifying clock holders, enduro riding book, layout supplies and clocks for clubs. Send 25t for catalog, N-DURO SPECIALTI ES P.o. Box 212 e • I Mallei;", S.C. 29662 ALTA • WORL£"'S FINEST Ultra-Lightweight Trials Bike (714) 286·1001 Available Now SAN DIEGO ALTA SUZUKI _4825 EI Calon Blvd. Rough Riders Accessories Make us your last stop on the way to th e desert and Elsinore or Perris. 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