YZ 250 Shock Rebuild

[dklassen]

I have to get my YZ250 shock oil changed and I looked in my Factory Service Manual but there were no instructions on how to rebuild the shock. My CR250 manual showed step by step instructions and a parts schematic. The only thing the Yamaha shows is how to replace the bearings on the top and bottom of the shock. It says that if the shock isn't working to just replace it. I checked the parts fiche and there are no internal parts listed, however I could buy a new damper assembly for $900. Yeah right! I can't believe that a modern KYB shock can't be rebuilt by a competent home mechanic. Where do the suspension re-builder's get their parts from? This seems just bizarre to me but I never looked into it until today.

[Woody_393]

The shock is going to be VERY similar to your old Showa, so if you've done that, it won't be much different.

I have used my manual, and this document with great success. --> Suspension Document - Shock on both showa and KYB shocks (from bikes to quads). The shock technology in the KYB and Showa hasn't changed much.

[hardcore_racer]

Stock replacement parts for stock shocks are hard to get because, like you said the manual says to replace at a $900 cost to you. Rebuilding the shock shouldn't cost more than $175 even if you have to replace all the seals and the seal head.

SSShocks.com

[dklassen]

This was just another reason why I ended up selling the bike. I realize that the shock could be rebuilt but honestly I can't believe that Yamaha would make this difficult. There has been a long list of problems I have had with this bike that I have never experienced owning more than 40 bikes over the years.