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Discussion Starter · #1 ·
I have decided to get a new spring for the shock on my 03 K1200LT and have it rebuilt. Not in a position to spend $1500 on a new aftermarket one since my input shaft bearing just went and already spent too much rebuilding the gearbox and changing the clutch. I already have a Hyper-Pro spring that just arrived today and should have my gear shafts with new bearings pressed on for full re-assembly by Friday. So I am looking for suggestions on the fastest, most effective way to have this done in a weeks time.

After a ton of calling around I was able to find a guy who can rebuild my OEM shock locally, but he wants $250-$300 for the rebuild, oil, gas seals, having it drilled at a machine shop (7-10 days usually) to tap a gas inlet or something. Plus it is $200 more if I want the re-valve with some fancy top of the line gold valve kit. It has 73,000 miles and probably has to be re-valved anyways right? Problem here is I want my bike back together by the 4th of July even if I have to pay for "next-day" shipping to a specialty shop who does these K12LT shocks often and can just "knock it out" and mail back in a few days, hopefully Friday-Saturday.

If anyone has suggestions on who to call I am open to ideas. $500 and 10 days makes me feel like I could almost mail this to some specialty suspension shop quick and have it back in half the time for less $$. Any ideas?
 

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Discussion Starter · #4 ·
Ended up getting the rebuild done, bike rides like a dream now. I dropped the shock and new Hyper-Pro spring off at Steve Mathewson's Suspension Systems at Sunny Side in Alexander NY. Took a few weeks for his machine shop guy to add a nitrogen port but my OEM shock is now serviceable and better than new. It was $360 for the modification having all new seals/shims/oil/ and $150 for the spring from MotorWorks UK so for $510 I would say after breaking in these last few days it was money well spent.

The only disadvantage here over ordering a new aftermarket suspension is the Wilber's & others would obviously fine-tune to your desired weight/load etc. with little adjustment required, so I did have to fiddle with the dampening for a few hundred miles to get the front and rear to work well together. After some small adjustments and a few times pulling over to tweak the adjusters she rides and handles better than when I bought the bike with 26k. It is like a new machine now!
 

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Discussion Starter · #8 ·
I wish that rebuilding the rear shock myself was an option. At 72k both were completely siezed up and bottomed out. My legs now feel a few inches shorter with new shocks, but after almost 2k miles my back feels like I'm 10 years younger.

Should have done this sooner as I have a feeling there is going to be some front suspension/steering work in order. Next time the tank is off for air/fuel filter I will be inspecting and doing a full re-torque on everything from the bars down. NY roads are brutal on everything suspension wise and after all of this work I no longer trust the assembly job this bike had after 19 years of bouncing these crappy roads surely something has shifted spec from bottoming out so often.

This machine is a pit of tedious labor but worth every bit of the extra effort just in the way it eats corners better than most sportscars can dream of, doing so in a soft comfortable fashion. What a dream to cut tight curves like warm butter again! :D
 
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