class plunger solenoid cap

[Vickersguy]

Per Prairie hammer's instructions, I cleaned up the seats in the CLASS valve body. They are fairly clean and square now, the corrosion is gone and the plunger contact area is shiny instead of grey with oxide. The challenge is to fix the rubber cap on the solenoid rod. I'm thinking a thin skin, 1/64th inch thick, of neoprene rubber, or maybe 1/32 , glued on with that rubber cement used for bicycle patches. With the groove that spring pressure and age has left in the plunger surface, being offset from center and all, i doubt it will seal even after what I did to the valve seats. Ideas are welcomed on this or a source for replacement caps. They are 8mm. dia.

Edited February 21, 2019 by Vickersguy
wrong word

[Chaharly]

Is your system leaking? Or slow to inflate? I found my leak was coming from the compressor.

[Vickersguy]

It's quick to inflate, quick to deflate. The front forks hold pressure for several hours, very slowly leaking out. Rear shock deflates in 60 seconds. The reed valve in the valve body is holding, so that leaves the solenoid valve seats. Also the plunger caps. If someone has ever found new caps, I'd love to know the source.

[Marcarl]

Anything that you would do to those caps would be a hit and miss, you would have to be dead on and then some more right on. I had the same thoughts at one time and then decided to leave as is and try it by leaving it alone. Everything worked just fine, so my concern at the time of old age and hard rubber was of naught. I would suggest you try the same. If you add anything to the surface and then have to remove it again, that would definitely ruin things.

[Vickersguy]

I've gone through the Dis-assemble - clean - reassemble - fail - dis-assemble -clean etc. cycle five times. No progress. I have noticed that the vent and front fork solenoids have a snap to them when I decrease pressure and the rear shock solenoid does not. Perhaps I have a voltage drop through poor solder joints in the control panel. There are no obvious or even subtle flaws in the valve body. All the solenoids work on the bench. Guess I'd better check the voltage to them on the bike. It should click when I decrease the rear shock pressure. Well something should and I got nada. Back to the book...

[Vickersguy]

Solder joints again. Six bad ones. All back together and seems to work. Pressure holding. Now back together. Sat in the captains chair and shook the handlebars. Loose as a goose. Have to tighten those neck bearings. Will this never end ???