Project-Kona Stinky Downhill Mountain Bike Restoration

Kona Stinky Downhill bike.  Bought as a renovation project for my son.

My youngest boy will be turning 13 years old next month and he will just be big enough (hopefully) to transition from his 24″ wheels Specialized Hotrocks, 3 inches of travel to a 26″ wheel, 6″ travel mountain bike-The Kona Stinky (small adult size).

I’ve had a saved searches on ebay and gumtree for sometime now and then the following ebay listing came up with a “Buy It Now” price and it was located within 3 miles of my workplace.




I particularly like “projects” as I think that it is good for my boys to see me buying good quality second-hand items and “doing them up” rather than thinking that they MUST have everything brand new.


Stripping down.

So over the last few weeks we’ve slowly stripped the Kona Stinky down.  I was pleased as my son actually started taking it apart himself, I showed him how it’s best to organise the parts and group them together and to put bolts into their original positions loosely-ready for the rebuild.

There have been no nasty surprises apart from a small crack on the seatpost up-tube, now this looks like it’s been caused by somebody having to get physical to get the seat post out (possibly due to corrosion) and then levering the seat-post and the tube.

I’m not too worried as I think I’ll be able to “stop-drill” a small hole at the end of the crack and then deburr and smooth the edges.

Stop-drilling is a technique that helps to stop a crack from getting longer because it re-distributes the forces equally around the edge of the crack and the drilled hole and prevents the forces which caused the crack to be focussed in one concentrated area.

Anyway, I’ll probably take some photos and write up the process when I do it and feature it on

Here’s a list of the components which will need replacing and why they need replacing:-

Component Reason Comments
Gear Shifters Cracked casings Open minded as to replacement parts.
Bottom Bracket Lots of play and wear in bearings. Might also need to get a special tool for removal.
Seat post The one fitted is too small in diameter. I think this is related to the crack (see text above).
Pedals They are not a matching pair and are worn.  I might have some spare ones knocking about.


The suspension bushes all seem fine.  When I looked at the Kona Stinky I was pleased to see that it had the following components:-

  • Hope 4 pot caliper disk brakes.
  • Hope Hubs (front and back)
  • Mavic Rims
  • Fox Vanilla Rear Shock
  • Marzochhi Forks

So this was a high specification bike for the time and luckily most spares are still readily available.


The dismantling of the Kona was relatively straightforward.  However the removal of the main pivot bearings was difficult.  I looked up on youtube how to remove the bearings (  Even with the help of this video the bearings were very difficult to remove even when using my big Record bench vice.

I think that this is mainly due to the fact that there are 4 main pivot bearings and they all need to be pressed out at the same time which creates a lot of friction and resistance.

I used lots of penetrating oil and enured that the socket I used to push against the bearings was in contact with the outer race.

I also used wood against the frame to protect it.

Kona Stinky Pivot Bearings Layout

Pressing out the main pivot bearings.

Using a bench vice to press out the suspension bearings (bushes) of a Kona Stinky Full Suspension Mountain Bike.
Using a bench vice to press out the suspension bearings (bushes) of a Kona Stinky Full Suspension Mountain Bike.

I’ll keep you updated…

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