KTM WP PDS rebound adjuster trap

[Nick DoleMember]

Thout I’d let you all in on a persistent problem with PDS rebound adjusters you can avoid. There is a rubber bung at the bottom of your shock that periodically needs to be removed and a good water dispersing lubricant squirted in. Failure to do this results in the rebound adjust snapping in two and a very difficult repair.
This is your rebound adjuster. Note the very thin section in the middle that has to turn the 8×1.0mm thread. Guess what happens when the thread rusts solid?

The screw fitting snaps off while you are trying to turn it.

Didn’t matter anyway as the adjuster snapped long ago…
Note this is on an SXS shock, happy to pay for the bling, never had it serviced till the adjuster seized…photo taken with shaft removed. What better way to spend a Thursday night.

[Nick DoleMember]

[Nick DoleMember]

New and old. Just needs a bit of steel wool and the old one will be good to go…not

[Nick DoleMember]

Hard to see it but this is a screw in guide for drilling the broken portion out. I use a left hand drill to try and spin the broken section free

[Nick DoleMember]

Now we have a concentric hole 30mm down a drilling ready to try and shock out with a left hand drill

[Nick DoleMember]

Nailed it. Why all the trouble you ask? Why not just buy a new clevis? You can’t. Have to buy a shaft assembly. $800. KTM AU don’t keep them in stock. Ex Austria. This SXS one is harder to get than a stock clevis. The rebound adjuster is cheap though. I keep them in stock. Always have half a dozen of them here. Common problem.
So when you get your shock serviced next time ask them if they disassemble the rebound adjuster and grease it up. Will save you a disaster like this.

[Adrian GaleMember]

Thanks for taking the time to post this up Nick.

So you just give the adjuster a hit with the WD40 after it gets a wash?

Galey

[Geoff ForshawMember]

Thanks for the tip Nick.
Cheers,
Lefty

[Nick DoleMember]

For what owners need to do, preventing this happening.
Remove the rear shock. 2 bolts. Flip it upside down. With a little hook/screwdriver/scribe prise the rubber bung out and inject some oil/rust preventative/CRC/HHS whatever you have into the cavity. Replace bung. Refit shock.
If it takes more than 15 minutes you are drinking too much while working.

[Nick DoleMember]

Just when I thought it was over, new adjuster fitted, packed with marine grade anti seize I checked the rebound adjuster needle.
Rusted solid. Sigh.
Must have been a great bike to ride! Ha. Not.

[AlexMember]

Great tip. For those not willing to remove shock I guess adjust the rebound adjuster periodically to keep it from seizing (okay that’s a real half arsed short cut even I wouldn’t do)

[Adrian GaleMember]

[attachment=3698]KTM3002008Rebuild021.JPG[/attachment]
Thanks Nick.
I lubed up the rebound adjuster while i had the shock out for a new Heim joint. It really is a 10 min job.

[murph the surfMember]

Doh.
Just put a new bush in Tims shock/swingarm
Didn’t even think of greasing the rebound adjuster. :blush:
Probably could be done in situe???
If not its only a matter of dropping the shock out again
Cheers
Murph

[Nick DoleMember]

pull the shock out again, 2 bolts, don’t be slack.

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