1997-1999 Honda CR250 – Rear Shock Rebuild Part 3: Body Assembly

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1997 - 1999 Honda Cr250 Rear Shock Rebuild Part 3

This is PART 3 of the step-by-step rebuild for your Showa KZ3P SA-1 rear shock.

You can find Part 1: Disassembly & Inspection here, and Part 2: Shaft Assembly here.

Remember, if you need parts and tools, you can get them HERE.

Click Here To Open The Rear Suspension Specifications In A New Window

1997-2001 Honda CR250 Rear Shock Assembly

  • Step 16: Back out the compression damper all the way to allow open oil flow between the reservoir and the body.
  • Step 17: Fill the reservoir halfway and make sure oil is flowing into the body.
    • *You will not see oil flow right away. Keep in mind that the compression damper is designed for forced oil flow, so let the shock sit for a few minutes.  If no oil is flowing, you may have a damaged damper.
  • Step 18: Install the valve cap and install the reservoir cap and bladder. You want to see the reservoir overflow, as this forces air from the reservoir.
    • Remove the valve cap and install the reservoir cap tool. Force the reservoir cap down far enough to expose the circlip groove.
    • Install the circlip, reinstall the reservoir cap tool, and pull the cap up to the circlip.
    • Remove the reservoir tool and install the valve stem.
    • Using a low-pressure pump, fill the bladder to around 40 to 60 PSI. This will seat the reservoir cap to the circlip, as well as force oil into the shock body.
  • Step 19: Fill the shock body halfway with oil.
  • Step 20: Install the shock shaft, working it up and down to remove any trapped air.  As you go, continue filling the shock body with oil.
    • DO NOT ATTEMPT TO SEAT THE SEAL HEAD!
  • Step 21: Release the pressure from the reservoir bladder and remove the valve stem. This will allow the bladder to compress, making room for the seal head.
  • Step 22: Using your seal head setting tool, pound the seal head into the shaft body just enough for the circlip groove to be exposed.
    • Install the circlip and valve stem.
  • Step 23: Inflate the bladder to 40 to 60 PSI to seat the seal head against the circlip.
  • Step 24: Pump the shock shaft and check for any obvious leaks at the seal head and reservoir.
  • Step 25: Install the shock body cap.  Hammer lightly around the edge of the cap, so it seats evenly.
    • *The punch holes in the cap also act as weep holes so you can check for slow leaks in the future.
  • Let the shock sit for a while, then come back and test the action again while checking for leaks.
  • Step 26: Install the spring, plate, and circlip. Tighten the preload adjustment nut, and fill with 130 – 150 PSI of NITROGEN!
    • *You will need to go to a shop for the nitrogen.
Step 16: Back out the compression damper all the way to allow open oil flow between the reservoir and the body.
Step 16: Back out the compression damper all the way to allow open oil flow between the reservoir and the body.
Step 17: Fill the reservoir halfway and make sure oil is flowing into the body.
Step 17: Fill the reservoir halfway and make sure oil is flowing into the body.
*You will not see oil flow right away. Keep in mind that the compression damper is designed for forced oil flow, so let the shock sit for a few minutes.  If no oil is flowing, you may have a damaged damper.
*You will not see oil flow right away. Keep in mind that the compression damper is designed for forced oil flow, so let the shock sit for a few minutes.  If no oil is flowing, you may have a damaged damper.
Step 18: Install the valve cap and install the reservoir cap and bladder.
Step 18: Install the valve cap and install the reservoir cap and bladder.
You want to see the reservoir overflow, as this forces air from the reservoir.
You want to see the reservoir overflow, as this forces air from the reservoir.
Remove the valve cap and install the reservoir cap tool.
Remove the valve cap and install the reservoir cap tool.
Force the reservoir cap down far enough to expose the circlip groove.
Force the reservoir cap down far enough to expose the circlip groove.
Install the circlip, reinstall the reservoir cap tool, and pull the cap up to the circlip.
Install the circlip, reinstall the reservoir cap tool, and pull the cap up to the circlip.
Install the reservoir cap puller
Install the reservoir cap puller
Pull the cap up to the circlip.
Pull the cap up to the circlip.
Remove the reservoir tool and install the valve stem.
Remove the reservoir tool and install the valve stem.
Using a low-pressure pump, fill the bladder to around 40 to 60 PSI. This will seat the reservoir cap to the circlip, as well as force oil into the shock body.
Using a low-pressure pump, fill the bladder to around 40 to 60 PSI. This will seat the reservoir cap to the circlip, as well as force oil into the shock body.
Step 19: Fill the shock body halfway with oil.
Step 19: Fill the shock body halfway with oil.
Step 20: Install the shock shaft, working it up and down to remove any trapped air.  
Step 20: Install the shock shaft, working it up and down to remove any trapped air.
As you go, continue filling the shock body with oil.
As you go, continue filling the shock body with oil.
DO NOT ATTEMPT TO SEAT THE SEAL HEAD!
DO NOT ATTEMPT TO SEAT THE SEAL HEAD!
Seriously
Seriously
Step 21: Release the pressure from the reservoir bladder and remove the valve stem. This will allow the bladder to compress, making room for the seal head.
Step 21: Release the pressure from the reservoir bladder and remove the valve stem. This will allow the bladder to compress, making room for the seal head.
Step 22: Using your seal head setting tool, pound the seal head into the shaft body just enough for the circlip groove to be exposed.
Step 22: Using your seal head setting tool, pound the seal head into the shaft body just enough for the circlip groove to be exposed.
Install the circlip and valve stem.
Install the circlip and valve stem.
Make sure the clip is seated
Make sure the clip is seated
Step 23: Inflate the bladder to 40 to 60 PSI to seat the seal head against the circlip.
Step 23: Inflate the bladder to 40 to 60 PSI to seat the seal head against the circlip.
The head will seat itself.
The head will seat itself.
Step 24: Pump the shock shaft and check for any obvious leaks at the seal head and reservoir.
Step 24: Pump the shock shaft and check for any obvious leaks at the seal head and reservoir.
Step 25: Install the shock body cap.  Hammer lightly around the edge of the cap, so it seats evenly.*The punch holes in the cap also act as weep holes so you can check for slow leaks in the future.
Step 25: Install the shock body cap.  Hammer lightly around the edge of the cap, so it seats evenly.*The punch holes in the cap also act as weep holes so you can check for slow leaks in the future.
Let the shock sit for a while, then come back and test the action again while checking for leaks.
Let the shock sit for a while, then come back and test the action again while checking for leaks.
Step 26: Install the spring, plate, and circlip. Tighten the preload adjustment nut, and fill with 130 - 150 PSI of NITROGEN!*You will need to go to a shop for the nitrogen.
Step 26: Install the spring, plate, and circlip. Tighten the preload adjustment nut, and fill with 130 – 150 PSI of NITROGEN!*You will need to go to a shop for the nitrogen.
Step 26.1
Step 26.1
Step 26.2
Step 26.2
Step 26.3
Step 26.3

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