fitting a 2004 zx10r shock to a zx6r b model

[two]

numpty guide to fitting a 2004 zx10r shock to a zx6r 2003-2004 zx6r b1

Parts required

1 x zx6r b model
1 x zx10r rear shock (2004 model)
1 x zx10r Suspension rocker arm sleeve - part no. 42036-1258
2 x zx10r Rocker arm seal - part no. 92049-1225
1 x J1 adjusting nut - part no. 92015-1953

http://img55.imageshack.us/img55/4888/f5jy.jpg (http://imageshack.us)


Tools required :
Various Alley keys - to remove bodywork
1x 14mm socket - right handside shock mount nuts
1x 13mm socket - left handside shock mount bolts
1x 22mm spanner - top suspension mount and J1 adjusting nut
1x long nose pliers - for the split pin
2x socket extension bar(s) - too make life easier
1x 3mm drill bit - to set the ride height

misc info
stock spacer is 6mm wide.. J1 adjusting nut is also 6mm wide
the 10r shock is 2-3mm shorter than a 6r shock

lets begin

1 - Removing the old shock

The first step is to decide how you are going to support the rear of the bike so you can remove the old shock.
There are several methods
a, ABBA stand
b, hung rear of bike from garage rafters
c, two step ladders and a large piece of wood under the pillion pegs and a cable tie for the front brake

Due to the fact I have no Abba stand and no garage rafters I will be using option c. Instructions with vary depending on the above.

Please ensure if you use the piece of wood method, you select a piece that can carry the weight of the bike, the last thing you what to happen is for the wood to snap. (learn from my mistake)

http://img55.imageshack.us/img55/3750/a8fl.jpg (http://imageshack.us)

As i was about to fit track fairing i've actually removed most of the bodywork.
If you were just changing the shock you really only need to remove the side fairing. (you could actually change the shock without removing the side fairing but the panels would just get in the way)

The first step is to losen and remove the nuts on the left hand side of the bike. (this will require a socket on the other side to enable this to be undone)
Now remove the split pin in the top mounting bracket and remove the 22mm top mounting bracket nut.

Now you can lift the rear of the bike without the weight of the rear wheel.
(and whenever you work on your bike your garage must look like a bomb has just hit it)

http://img55.imageshack.us/img55/6604/b7xo.jpg (http://imageshack.us)

Now remove the remaining top and lower shock mounting bolts,

From the left side of the bike lift the rear shock up the toward you give the shock a slight rotation so the resevoir does hit the rear subframe.

this is the upper mounting with the shock removed

http://img55.imageshack.us/img55/268/c2rl.jpg (http://imageshack.us)

2 - Matching the standard ride height

Remove the standard zx6r b1 6mm ring spacer from the shock mounting bracket
and replace it with the adjusting nut from a J1.
As the zx10r 2004 shock is 2-3 mm shorter than a zx6r b shock you need to add an additional 2-3 mm using the adjusting nut.
To get the additionial height adjustment required use a drill bit of the require diameter as a feeler guage.

http://img55.imageshack.us/img55/2496/h1vn.jpg (http://imageshack.us)

3 - Change the lower rocker linkage sleeve

As you may or maynot be able to see in the picture, the lower mounting fork on the zx10r shock is 1-2 mm narrower than a zx6r shock.

http://img55.imageshack.us/img55/981/e8ck.jpg (http://imageshack.us)

Push the sleeve out of the mounting in the rocker linkage and remove the rocker arm seals

http://img55.imageshack.us/img55/6999/g2kr.jpg (http://imageshack.us)

Install the zx10r rocker arm sleeve and seals. (reverse of removal)

4 - Install New shock

The installation of zx10r shock is simply the reverse of removal. (haynes maual eat your heart out)

http://img55.imageshack.us/img55/226/i0zg.jpg (http://imageshack.us)

http://img55.imageshack.us/img55/156/j2ct.jpg (http://imageshack.us)

I will provide feedback once I ridden with the shock for a while. (and had a tweak to suit the roads i normally ride on - bumpy ) Hopefully also get to do some back to back testing against a standard b1 too ;)

[harriebird]

cool, nice work! i fitted a hagon lowering shock to my 748, with the kind assistance of drew's ABBA stand, easy peasy and really enjoyed doing it.

next stop is to do a CBR600 shock on my NC29 :grin2

[J-Gates_ZX6RNinja]

good work there!

Interested to see what kinda difference its made

[ALBERE]

harrie wat diff will the 600 shock do?

[Lateshift]

errr stiffen it up a little and very likely give it a bit more adjustability ;)

[harriebird]

harrie wat diff will the 600 shock do?

as lateshift says, mainly to stiffen it up, the NC29's shock is known for being soft as soft can be (dunno about you but mine is murder over speedbumps)

apparently the CBR600 F3 is the one to get. it's a doddle to do (or was on the 748 - but the shock is a bit more open and easy to get to!) if you have an Abba stand, i just gotta get my ass in gear.

the shocks are quite cheap to get hold of second hand but i need to find out how much difference it will make to the seat height otherwise it's pointless...i can take it a bit higher but too high and it will be kind of counter-productive....

have a look on www.400greybike.co.uk (http://www.400greybike.co.uk), there's loads about it on there

[ALBERE]

nice one sounds good

[ALBERE]

i mite hav todo that id like more height and harder suspension

[two]

good work there!

Interested to see what kinda difference its made

its an improvement...

with the standard b1 shock its not possible to set static and dynamic sag figures (you can set one or the other)

the standard b1 shock kicks off every little bump, and it also a reason the bike like to go into huge tank slappers

the bike handles bumps better and i haven't had a huge slap since fitting the zx10r shock

[J-Gates_ZX6RNinja]

How much did it cost all in to do?

[two]

i only paid £40 for the zx10r shock (which was setup by the previous owner by k-tech for track riding, lucky he weighs about the same as me)

the rocker arm sleeve was less than £3, I've actually changed the seals back to the zx6r seals (so the zx10r seal aren't needed)... and the adjusting nut was all of £1.50 (the kawa race rear ride height kit is over £100)

Is your bike a J1 or J2...? looks like a J2 in which case you have a spacer instead of a nut under the top shock mount... buy the nut and raise the rear height 8-10 mm... trust me the bike will turn in better and hold a line better too... (i had a J1 which has the nut and it made a huge difference once the height was raised)

[J-Gates_ZX6RNinja]

My shock has ride height adjustment anyways im sure it does... I cant actually be assed to get up tho and have a look!

I have been told about a good set up here
http://www.johnodell.eclipse.co.uk/zx6rg-susp.htm

Which is what I intend to use while testing the **** out of my new rubber this sunday! lol

[two]

My shock has ride height adjustment anyways im sure it does... I cant actually be assed to get up tho and have a look!

I have been told about a good set up here
http://www.johnodell.eclipse.co.uk/zx6rg-susp.htm

Which is what I intend to use while testing the **** out of my new rubber this sunday! lol

the PB setting work well.. did for me :)