pjweimer
Member
Our 2014 RT Limited's ACS system started giving us problems about a week ago. Started out with the compressor making quite a racket each time it ran and it was running very frequently. When we returned home I checked the pressure in the system via the schrader valve under the seat. Now this was maybe 15 minutes after shutting the bike down. Pressure = 0 psi. Not good.
I added 40 psi via garage compressor. Twenty minutes later, 6 psi. Not good. Removed side panels to gain sight access to the area of ACS components (top of swing arm, in front of rear shock). Grabbed a spray bottle filled with soapy water that I use to check for leaks and sprayed all air hose connections that I could see. Put another 40 psi charge into ACS. Could see no bubbles. Now from the side one can not see the top of the air spring. So I'm thinking the loss of air is either the air spring or the check valve on the compressor (as that would allow the leaking air to escape back into the compressor and not show any exterior bubbles).
Trying to get more information I started the bike, released the parking brake and put it into first gear. This should have initiated the ACS to operate. The compressor did not start pumping. System pressure stayed at 0 psi. So I figure the compressor has burnt up from running nonstop attempting to build pressure into a leaking system.
So I order a new air spring and check valve from my dealer and a Rock Guard from Doc Humphreys. Figured I would access the compressors status and may be able to rebuild it or, if I could not rebuild it I would order one from a third party. Doc had mentioned one in a post here on the forum.
So I start the tear down to get to all the involved components. I followed, pretty much, the tear down process shown in the videos that Doc has posted on his web site (dochumphreys.wixsite.com/roadster/install). Thanks Doc! When I got the air spring out I submersed it in my ultrasonic cleaner as it is filled with soapy water and just blew a bit of air into it. No bubbles. Need to put the garage compressor on it and get it up to 80 - 100 psi as I had not yet done a real test of its integrity.
Pulled the compressor out and removed the check valve off of it. Blew in one end, OK, blew right through. Blew in other end, blew right through. Not good. Tossed it in the ultrasonic for 10 minutes. Blew in that last end again, no air through. Check valve seems to have been stuck open. Loss of air may have been back through it into the compressor and could account for eventual malfunction of compressor.
Pulled the inspection plate off of the compressor to see if I could identify the source of the noise we had heard before it seemed to give up the ghost. No wonder it was now quiet and not producing compressed air, the connecting arm to piston had come off of the motors shaft. Appeared the set screw had backed off and left the assembly to disassemble. Put 12 V on the leads and the motor ran smoothly.
But no amount of pressure would let me move that set screw either in or out. Rounded off two 2.5 mm allen wrenches trying to tighten it up and/or remove it.
So today I will pressurize the original air spring to confirm its integrity, clean up the areas on the bike to prepare for reassembly and order the third party compressor from Amazon.
Here's a few photos from yesterdays efforts.
Doc's Rock Guard, New Air Spring, original air spring with air hose still attached to mounting bracket
Original air spring extended to show accumulation of debris at top of unit. Bottom of unit looks good. Still needs to be pressure tested.
Label on bottom of new air spring
Status of the bike
Inspection plate removed from compressor showing connecting rod disconnected from motor shaft
I will post follow ups as I complete this job.
I added 40 psi via garage compressor. Twenty minutes later, 6 psi. Not good. Removed side panels to gain sight access to the area of ACS components (top of swing arm, in front of rear shock). Grabbed a spray bottle filled with soapy water that I use to check for leaks and sprayed all air hose connections that I could see. Put another 40 psi charge into ACS. Could see no bubbles. Now from the side one can not see the top of the air spring. So I'm thinking the loss of air is either the air spring or the check valve on the compressor (as that would allow the leaking air to escape back into the compressor and not show any exterior bubbles).
Trying to get more information I started the bike, released the parking brake and put it into first gear. This should have initiated the ACS to operate. The compressor did not start pumping. System pressure stayed at 0 psi. So I figure the compressor has burnt up from running nonstop attempting to build pressure into a leaking system.
So I order a new air spring and check valve from my dealer and a Rock Guard from Doc Humphreys. Figured I would access the compressors status and may be able to rebuild it or, if I could not rebuild it I would order one from a third party. Doc had mentioned one in a post here on the forum.
So I start the tear down to get to all the involved components. I followed, pretty much, the tear down process shown in the videos that Doc has posted on his web site (dochumphreys.wixsite.com/roadster/install). Thanks Doc! When I got the air spring out I submersed it in my ultrasonic cleaner as it is filled with soapy water and just blew a bit of air into it. No bubbles. Need to put the garage compressor on it and get it up to 80 - 100 psi as I had not yet done a real test of its integrity.
Pulled the compressor out and removed the check valve off of it. Blew in one end, OK, blew right through. Blew in other end, blew right through. Not good. Tossed it in the ultrasonic for 10 minutes. Blew in that last end again, no air through. Check valve seems to have been stuck open. Loss of air may have been back through it into the compressor and could account for eventual malfunction of compressor.
Pulled the inspection plate off of the compressor to see if I could identify the source of the noise we had heard before it seemed to give up the ghost. No wonder it was now quiet and not producing compressed air, the connecting arm to piston had come off of the motors shaft. Appeared the set screw had backed off and left the assembly to disassemble. Put 12 V on the leads and the motor ran smoothly.
But no amount of pressure would let me move that set screw either in or out. Rounded off two 2.5 mm allen wrenches trying to tighten it up and/or remove it.
So today I will pressurize the original air spring to confirm its integrity, clean up the areas on the bike to prepare for reassembly and order the third party compressor from Amazon.
Here's a few photos from yesterdays efforts.
Doc's Rock Guard, New Air Spring, original air spring with air hose still attached to mounting bracket
Original air spring extended to show accumulation of debris at top of unit. Bottom of unit looks good. Still needs to be pressure tested.
Label on bottom of new air spring
Status of the bike
Inspection plate removed from compressor showing connecting rod disconnected from motor shaft
I will post follow ups as I complete this job.
