ES Shock Removal Help

[CraigRegs]

I'm trying to get my shock removed to send off to EPM Performance (viewtopic.php? p=163752&hilit=ES+shock#p163752) and have reached a hurdle. I'm having trouble removing the DC motor coupler and can't find the stepper motor coupler. As a picture is worth a thousand words, this video may save me a lot of typing.



Second bit: The FSM doesn't say as much, but it appears the shock must be lifted up for removal rather than dropped down. The swing arm doesn't appear to have room to allow the shock, with its ES appendages, to drop through. So does the metal tray that cradles the DC motor have to be removed to create room to lift the shock up? Again, the manual says nothing about it. Or have I missed something?

Thanks to the collective for any help.

[raYzerman]

Caveat, I have not done this nor am I likely much help.......... my guess is the connector you're looking for is on the stepper motor itself??

[Intech]

Like Ray Ray said, I haven't done this before either, so not much help. I will say that the scope I have that connects wifi to my phone has been a huge help in situations like this. It can see around things that you can't. It was pretty cheap and works great. I'll get the info on it and post it here. Most of the connectors that are "in the open" like that one have a rubber gasket in them that make them tight, It should have a tab to depress like most of them, but they put it where it is impossible to get to. I will be interested in the outcome as I expect I will be doing the same thing sometime in the future. I will cross 100k tomorrow.

[Intech]

The Scope I am using is: https://a.co/d/1wqcg3L

[CraigRegs]

Bob, I have just such a scope and forgot about it! I’ll be digging it out.

Progress update: Turns out I had the “hidden” connector (with blue tape in photo) disconnected. It’s at the rear of the shock, but the cable is clamped to a panel (seen at top of photo below) so it doesn’t have any slack and can’t be pulled through.


So it appears the shock must come up to get out. To do that, the plate (indicated below) supporting the DC motor has to come out. The shock is on the left of the photo.


No mention of this plate in FSM, nor is it even show in the illustrations. But there are 2 allen-head bolts on each side and maybe a couple more that should free it. This is bottom of the plate on right side. Second shot is the left side.




That’ll be tomorrow. Need to get this off to EPM quickly to allow time for reassembly. But that’s a discussion for another day.

[bigjohnsd]

The Scope I am using is: https://a.co/d/1wqcg3L

With a scope like that you can moonlight as a proctologist!

[wheatonFJR]

The Scope I am using is: https://a.co/d/1wqcg3L

With a scope like that you can moonlight as a proctologist!

One of his life's goals for sure.

[raYzerman]

What happens at tech day stays at tech day, JSNS.

[CraigRegs]

The Scope I am using is: https://a.co/d/1wqcg3L

With a scope like that you can moonlight as a proctologist!

One of his life's goals for sure.

You sound pretty sure I haven't checked that box already (so to speak...)

[escapefjrtist]

All I can offer is good luck Craig. I've removed one ES shock from a wrecked '16 so we were able to essentially strip the back half of the bike. I do remember it was a big PITA to remove w/o a lot of disassembly.

Edit to add: If you need a replacement, I think that ES shock is still available. Had approximately 24k miles.

~G

[CraigRegs]

When all George can offer is “good luck” and “ It’s a PITA” you know you’re in deep.

And so I’ve reached a tipping point. I think if I can disconnect the hose shown below , I can twist the shock out from below. My question is, what’s in this hose? Oil? If I disconnect it, what should I expect? A few drips? A shower? Irreparable damage?


Its attached to the preload adjusting pump at the other end.


Of course I can easily disconnect the hose, but if there’s leakage, that begs the question of compensating for that during reassembly. If disconnecting the hose isn’t feasible, then I’m going to abandon the shock rebuild and start buttoning it back up. To take out the shock from above would require removing the brake pump, which means draining all brake fluid and that’s more than I can expect to put back together before Reuben Run.

[escapefjrtist]

That's the hydraulic preload, don't touch it Craig! If you open the line you'll lose oil and it would somehow have to be refilled and properly bled.

I want to say we removed the shock and associated parts from the top. I don't remember us needing to remove any lines from the braking system. Have you closely studied the FSM and followed the steps? I have an ES service manual and can take a look at it after work. (You do remember work, right?)

~G

[raYzerman]

Can't tell fully, but that tapered "reservoir" is holding the fluid that operates your preload collar on the shock. Of course you can undo the hose, lose some oil and fix it later...... however, when you get the shock back from rebuild, you can't remove the hoses..... it will have been refilled...... you've got to find the way it comes out from the top and back in again........
Removing ABS..... nothing about that in the FSM........

More than one way to skin a cat...... what if you removed the entire swingarm........? Easier than screwing with the ABS....

[CraigRegs]

Just finished a call with George and we think the way to skin this cat is removing the swingarm, as raYzerman suggests. That will provide clearance to allow the shock and attached plumbing and electronics to lift up and out. Unfortunately, I don't have time to do that, get the shock rebuilt and reinstalled before leaving 8/30 for Reuben Run. So, I'll start putting parts back into the general vicinity of whence they came, and hope to tear back into this after I return from SFO in November.

[fontanaman]

I just happened upon this post today. Now I am mostly convinced I will not being removing the shock on my 17 ES.

Craig why do you want to send the shock to EPM Performance? As critic of the ES shock I am always interested in improved suspension.

[CraigRegs]

I just happened upon this post today. Now I am mostly convinced I will not being removing the shock on my 17 ES.

Craig why do you want to send the shock to EPM Performance? As critic of the ES shock I am always interested in improved suspension.

WIth 110k on it, it's beginning to feel spongy. I like the ES adjustability, but a new replacement is $3K+. So rather than replace with a new one or an aftermarket that doesn't accommodate the ES function, I thought I'd try the rebuild for a few hundred bucks.

[SkooterG]

Well, it's a damned good thing you are retired now and have time to do this and produce a painstakingly detailed video for the rest of us. Just saying.....

[Canadian FJR]

Are you able to remove the rear sub frame and pull it out from the top. That’s the way one of the Ohlins on an earlier Gen had to be installed.

http://www.fjr1300.info/howto/ohlins.html



Canadian FJR

[SkooterG]

Are you able to remove the rear sub frame and pull it out from the top. That’s the way one of the Ohlins on an earlier Gen had to be installed.

http://www.fjr1300.info/howto/ohlins.html



Canadian FJR

That is OLD information. I have removed/installed many an aftermarket shocks and it's a relatively straightforward and easy process to remove them out of the bottom of the swingarm. Removing the rear subframe would be the LAST thing I would want to do. I would rather remove the swingarm.

[raYzerman]

Might be an issue if there is an attached reservoir at the top of the shock that won't pass down through the swingarm..... but I'd say removing the swingarm is a bit less work than removing the subframe???