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How do you rebuild the CIDLI on GTR

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  • How do you rebuild the CIDLI on GTR

    Hello folks,

    Looking for some guidance on how to rebuild the suspension knuckles on the GTR.

    I remember there was a tool kit available from DDM of the special tools needed, but they don't seem to carry them anymore?

    anyone know how this is done?


    I just picked up a almost mint GTR from craigs for 625 but I think the Original owner Loosened the center bolt instead of the 4 set screws, now the rods are bulging out on the rotor side and the front fork barely gives when I jump on it.

    I tried putting some oil on the rods and then tightening the center bolt but the rods seem to get pinched instead of slipping back inwards....

    so I thought I would ask for advice before I continue to tinker.

    Thanks in advanced guys!

    ~Allen~
    GTR 46 dominator
    GTR 46 w/ rhino
    GSR29 4 bolt Zen w/torque pipe
    GSR 25 stock

  • #2
    Allen, rebuilding the fork is no easy task.
    If the front end is stiff then that means the rods are still doing their job. Stock rods are relatively stiff to begin with.
    If you are unhappy with the excess of protruding rods you can simply just trim it away. It is a negligible amount and will not affect its performance.
    Unfortunately though once the water soluble lubricant used during assembly evaporates from the area where the rod contacts the knuckle it is nearly impossible to move it laterally without damaging the inner knuckle. An install tool would be of no help to you as it would result in crushing the Delrin.

    Comment


    • #3
      if thats the case couldnt one in theory bathe the assembly in water-soluble lube overnight and have them slip right in/out
      Originally posted by traxxas7137
      Or it leaned out so it's smooth power VS gurgle gurgle EXPLODE

      Comment


      • #4
        Originally posted by maxman View Post
        if thats the case couldnt one in theory bathe the assembly in water-soluble lube overnight and have them slip right in/out
        NO. Once the rods are installed there is no "slipping out". You have to destroy the rods by drilling them out if you want to disassemble the CIDLI suspension.

        First pic is after I cut three of the rods down to the block. Second pic is during the drilling process. You have to start out with a small drill bit and work your way up to 3/8" or larger, and it is quite the mess. And you have to use a slow speed. At high speed the drill actually melts the rods and turns everything into a hot gooey mess.
        Attached Files
        CP......
        HOW we ride today, may determine IF we can ride tomorrow

        Comment


        • #5
          Originally posted by Master Shake View Post
          the front fork barely gives when I jump on it.
          Sounds like every gtr I have ridden or stood on. They barely compress even when I 200+lb jumps on it. The back end is where all the compression is at.
          My Constitutional Rights Don't End Where Your Feelings Begin

          Comment


          • #6
            My suggestion would be DON'T take it apart until you have exhausted every other option. We have re-done 3 so far, (1 of those twice). If you have the correct diameter rods it is really difficult to get them installed, even with the overkill installer we made. Use ZEP 45 or Triflow or some other Teflon based spray lubricant. Spray around the rods liberally, re-install cover with set screws backed almost out, and nut on center bolt loose. Now get one of your fat friends (250 lbs like my size) to jump up and down on the deck. Like they're trying to break it in two. Spray again, repeat. The lube needs to get entirely around the rods so that they roll freely. Leave center bolt just snug and set screws out or almost out and ride it.

            Comment


            • #7
              Snapondick did this to one of our friends brand new Trailrippers that barely moved and now he has a soft plush ride... Do not buy the Rods from DDM like I did,mine was so soft I bottomed out the frame, They are not the correct diameter and are tooooo soft

              Comment


              • #8
                Snap, SJ,

                1)when you say re-install cover do you mean the billet cap with the set screws? if I take this cover off will I be able to put it back on with out special tools or great difficulty? at what point does it require special tools or hard labor to put back together????

                2) are you saying the bolt in the center should be loose? I have two GTR's and on the other scooter the bolt has been tightened down much further to show more exposed threads.

                So I started cranking down on the center bolt to tighten to the visual specs of my other GTR and it seemed to make the little suspension play it had, disappear completely.

                3) What exactly is done by tightening down the center bolt?

                I read in the owners manual not to touch it, to just use the 4-setscrews. I'm thinking the previous owner did not head this advice and backed the center nut out.

                is the assembly at risk of falling apart with this center nut backed out so far?

                4) what does your over kill installer look like and how is it made?


                Sorry for so many questions !!!

                But thank you so much for the answers!!!!
                GTR 46 dominator
                GTR 46 w/ rhino
                GSR29 4 bolt Zen w/torque pipe
                GSR 25 stock

                Comment


                • #9
                  also, does no one else remember the tool kit DDM offered for repairing the CIDLI???
                  GTR 46 dominator
                  GTR 46 w/ rhino
                  GSR29 4 bolt Zen w/torque pipe
                  GSR 25 stock

                  Comment


                  • #10
                    The DDM kit was made by TTB if I remember right. The cover I refer to is the aluminum square with the 5/8" coarse set screws. Just remove it and it is pretty self explanatory. Nothing is going to fly apart, yet. A puller is needed only when installing new rods. If the complaint is to stiff, spray it like I said before. Install cap over the rod ends before you jump up and down on it. Set screws can be backed way out. After it loosens up, snug up the center nut as needed. 1/8" to 1/4" max gap on each side is OK.

                    Comment


                    • #11
                      Plenty remember the install tool, but you can't get them anymore and that's life. Someone tried to reproduce it, but like his other endeavors never completed the task in full. He is no longer allowed on this site for other reasons.

                      If it were me and I needed to rebuild the GTR suspension, I would make my own install tool. I'm sure someone could post a pic of all the parts as well as provide some specs.
                      Hell Fab

                      Comment


                      • #12
                        http://www.billetboard.com/showthrea...allation-Guide

                        Comment


                        • #13
                          Thanks dellucha

                          I added some tags to your "how to thread", for some reason I tried searching before posting this and no matches were found, maybe the search is cap sensitive?

                          Your thread helped me immensely!
                          GTR 46 dominator
                          GTR 46 w/ rhino
                          GSR29 4 bolt Zen w/torque pipe
                          GSR 25 stock

                          Comment

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