Rear air shock hose

[newrider1949]

Hi guys, I need to replace the rear shock air line as it's leaking/split. I know progressives are supposed to be better but I'm not going that route. Shocks seem fine, just the hose that leaks.
I just went to my local hydraulics shop(s) and they couldn't match the metric thread of the fittings so no help. I'm tempted to try repairing the split in the line but I'd prefer to replace the hose. The ends seem to be the problem. Has anyone managed to make a new air line?

[GrandpaDenny]

Your best bet might be to contact Carl Leo voyagerparts@bellsouth.net for a whole assembly. Or you could try eBay, but I don't think I've ever seen an air hose assembly on there.

[newrider1949]

Looks like the thread size on the hose and shock connections is M3 x 1 and not easy to find fittings that size. All M3 ones I found were M3 x 0.5.
I'm going to have a go at repairing the hose today with rubber CA. Will see how it goes.

Thanks for the link, will send an email

Larry

[VoyKimmer]

I changed my rear shocks over to progressive 412HD. Much better ride, no air is nice and not that expensive.
Worth the upgrade.

[newrider1949]

Fixed the hose, re-installing tomorrow, lets hope it worked!

The hose was split near the fitting. I washed down the area with acetone then used tire repair cyanoacrylate, basically black superglue that has carbon and rubber ingredients. It's not flexible as far as I can tell but as the break was so close to the fitting I don't think it would have to flex at that point.

Repair looks solid and hard, like a black version of a krazy glue/baking soda fix.

Larry

[triton28]

Larry;
I just measured the smaller of the 2 fittings on the front fork air line, the fitting which screws into the balance tube between the 2 fork tubes and I measured 8mm by 1.0m tpi.
I believe all 6 of the smaller hose ends are the same size and the 2 large fittings which contain the schraeder valves, 14mm X 1.25 tpi, are the same size as each other.
So if your repair does not work there are hose barb to metric thread fittings available so one could possibly make a new hose run using barbed rather than swaged fittings. I have attached a link to a likely candidate.
Dave

https://www.fittings.space/fittings-by- ... r%20M8x1.0

[newrider1949]

Larry;
I just measured the smaller of the 2 fittings on the front fork air line, the fitting which screws into the balance tube between the 2 fork tubes and I measured 8mm by 1.0m tpi.
I believe all 6 of the smaller hose ends are the same size and the 2 large fittings which contain the schraeder valves, 14mm X 1.25 tpi, are the same size as each other.
So if your repair does not work there are hose barb to metric thread fittings available so one could possibly make a new hose run using barbed rather than swaged fittings. I have attached a link to a likely candidate.
Dave

https://www.fittings.space/fittings-by- ... r%20M8x1.0

Front no problem, it's only the rear that was loosing pressure through the broken hose. The fittings at each end of the hose measure 3mm, M3 x 1 thread which is impossible to source, at least so far. Removing the hose wasn't too bad but reinstalling it was a PIA ...seemed impossible to refit without twisting the hose. The only way I could get the repaired hose back in place was to remove the valve from the fairing then unclip the aluminum manifold and bring the whole fairing end assembly out of bike. After first screwing in the fitting at the rear shock, I could then screw the other end into the manifold without twisting the hose. Then it was pretty straightforward to relocate and mount the valve back into the fairing.

Good news is it's fixed. I put 25lbs into the rears and it's holding. Sprayed soapy water everywhere and no leaks.

Larry

[newrider1949]

Shocks lost pressure over the week so removed hose again and wrapped the connections (4) up to the first 3" of hose with that silicon stretch tape that sticks to itself, the stuff used to repair hoses.
Did a really tight wrap starting away from the fitting and worked my way down to the connector - I think the secret with this stuff is to start away from the area that has a leak and cover the leaking area with a good tight stretch. Starting a wrap at the leak doesn't get enough tension to the area as the initial once-around can't be that tight. Anyway, it seems to work now, sprayed down with soapy water and no bubbles seen.

Still can't believe there isn't a hose fitting anywhere in the world made in M3 with a 1 mm thread. All seem to be M3 x 0.5 nothing even on aliexpress!

Larry

[newrider1949]

Larry;
I just measured the smaller of the 2 fittings on the front fork air line, the fitting which screws into the balance tube between the 2 fork tubes and I measured 8mm by 1.0m tpi.
I believe all 6 of the smaller hose ends are the same size and the 2 large fittings which contain the schraeder valves, 14mm X 1.25 tpi, are the same size as each other.
So if your repair does not work there are hose barb to metric thread fittings available so one could possibly make a new hose run using barbed rather than swaged fittings. I have attached a link to a likely candidate.
Dave

https://www.fittings.space/fittings-by- ... r%20M8x1.0

Well there's nothing like an old fool and for sure I fit the bill! I should have paid more attention to your advice rather than staying with what I was "told"
It's a bit late to thank you Dave, but thanks a bunch anyway!

The kid who I first spoke to at the hydraulic hose place was the one who "measured" the fitting and told me it was M3 x 1.0 so as the hose company are the professionals, that's what I went searching for. Not finding that anywhere so spent a week and about $50 trying to repair the OEM hose. Finally pulled out my vernier last night and measured the fittings and saw that they were, as you said, M8 x 1.0 not M3 ...can't believe I was so dumb as to not measure them myself!

Anyway, Amazon had this kit which has the four fittings I need and it arrives some time tomorrow. with a few new o-rings I should be back in business.

https://www.amazon.ca/dp/B0982P47N7/?

Larry

[triton28]

Well that kit looks like the cat's meow; and it has the right number of threaded connectors to complete the rear air line system.
Let us know how it works if you would.
Dave

[newrider1949]

The kit is partially complete and arrived tonight. Small issue though - because the schraeder end fitting isn't the same I had to order a couple of other bits to get from the 4mm air hose to the schraeder fitting. I assumed the short section of OEM hose from the manifold also had a M8 x 1.00 that screwed into the M14 x 1.5 terminal, but in fact the hose is crimped directly to the M14.

What I ordered to use at the valve end was a push-to-fit 4mm to 1/4" NPT female adapter and a schraeder valve with a male 1/4" NPT thread.

https://www.amazon.ca/gp/product/B0B3DJLFYZ and https://www.amazon.ca/gp/product/B0CXSYNW7R

Larry

[newrider1949]

Small modification to fit new schraeder assembly to existing outlet. Not a huge deal but had to make up a washer/plate to bolt it up and leave enough of the valve protruding so that a typical air line inflator could fit.

Anyway, all done -no leaks and looks good.

I'm about 210 lbs so any recommended pressures front and rear for a guy my size?

Larry