DJ123
23-08-12, 08:26 PM
I recently changed mine, and found very little info on how to fit a rear shock with a 45 degree reservoir. I figured this maybe useful and so you know what to expect when coming to do it, or considering it.
I knew i had to cut the battery tray, so the 1st thing i did was remove all fairing from the rear of the bike and the undertray.
http://i515.photobucket.com/albums/t358/focus550/IMG-20120813-00045.jpg
Next, i lifted the rear of the bike to take weight off the shock. It is also good to wind off the preload on the spring. I then started to undo the bolts. At the top of the shock is a 14mm nut and bolt. Remove the nut, leave bolt in situe. (all bolts enter the bike from the left hand side) On the other end of the shock is this;
http://www.turnsocket.com/sites/default/files/imagecache/classified_full/knuckle1_0.jpg
The hole closest to the dog legs (in this picture) is where the shock bolts into. You may need to adjust the height of the rear/swingarm to get this bolt in clear view. This bolt is a 14mm head, and 14mm nut. Again, loosen this off and remove the nut. Once you have done this check to see if there is any tension on the shock (whether it's still still under compression or being pulled) If not, then you now need to loosen the lower dog bone bolt, shown in the picture. You may need to adjust the rear to remove the bolt and take tension off the joint.
You should now have an empty gap
http://i515.photobucket.com/albums/t358/focus550/IMG-20120813-00046.jpg
Now the shock is out the way, remove the monoshock link form the frame, you need to remove the side stand safety switch (2 10mm bolts, tilt the switch towards front of bike and then lower). The nut and bolt is again 14mm & 17mm nut. There is a washer located either side of the linkage between the frame, do not lose these! With the linkage free inspect the bearings for play and condition, re grease if necessary. Remove the dog bones from the swingarm and check the bearings in the swingarm mount, again regrease if necessary.
Also check the bolts and spacers/sleeves for wear and play. Put them through the bearings in which they live and make sure there is no/minimal movement.
clean up and then place the relevant sleeves back into the bearings in which they came from.
Clean up and grease bolts ready for assembly.
Now with the battery tray you need to cut the from left hand corner. Not completely off, just an inch upwards, inch backwards and half way across to the centre (there is a light moulding line)
http://i515.photobucket.com/albums/t358/focus550/IMG-20120814-00050.jpg
http://i515.photobucket.com/albums/t358/focus550/IMG-20120814-00051.jpg
I have installed a layer of foam beneath the battery to raise it up. This ensures it is clear of the reservoir and it is not pincered between the lower of the seat and the battery box/shock reservoir. Check your clearence on the underneath of the seat. Remember when you are sat on the seat it will sit slightly lower. I will get pictures of my set up shortly.
This is enough room for the reservoir to 'fit' inside the battery box. To test the gap is big enough, relocate the undertray/battery box and install the upper bolt of the shock. Trim more off if necessary.
You may need to get a new lower bolt for the shock. I had to get a new nut and bolt. Remember they MUST clear inbetween the dog legs, there is not much of a gap either side. I ordered a new nut and bolt from Suzuki. The bolt must have a high shear stregth as the force is pushing laterally on the bolt.
BOLTS ARE INSERTED FROM THE LEFT HAND SIDE OF THE BIKE
In order to install the new shock, put the bolt through the top mount to suspend the shock. Then bolt the monoshock linkage to the frame (not forgetting the washers). Line up the lower shock to be bolted on to the linkage. Remember to have it facing the right way if you have a rebound adjuster. Now line up the dog legs-it is easier to locate the top bolt 1st, then the lower. Again, you may need to adjust the height of the swingarm to locate the bolts into the holes. When All bolts are in and lined up, you can start to do them up. Remember to torque them up correctly! They do not need to be graunched up. Once all bolts/nuts are done up. Check for free play. Lower the rear of the bike so there is weight on the wheel. Lift up the rear of the bike, check for knocking in the joints/bolts. Push down and do the same.
When you are happy, start to put the bike back together. Take it slow with a new shock on, and adjust as necessary on the next few ride outs.
I have probably missed a few things out, or not explained them properly. If so please tell me and i will edit it accordingly.
I knew i had to cut the battery tray, so the 1st thing i did was remove all fairing from the rear of the bike and the undertray.
http://i515.photobucket.com/albums/t358/focus550/IMG-20120813-00045.jpg
Next, i lifted the rear of the bike to take weight off the shock. It is also good to wind off the preload on the spring. I then started to undo the bolts. At the top of the shock is a 14mm nut and bolt. Remove the nut, leave bolt in situe. (all bolts enter the bike from the left hand side) On the other end of the shock is this;
http://www.turnsocket.com/sites/default/files/imagecache/classified_full/knuckle1_0.jpg
The hole closest to the dog legs (in this picture) is where the shock bolts into. You may need to adjust the height of the rear/swingarm to get this bolt in clear view. This bolt is a 14mm head, and 14mm nut. Again, loosen this off and remove the nut. Once you have done this check to see if there is any tension on the shock (whether it's still still under compression or being pulled) If not, then you now need to loosen the lower dog bone bolt, shown in the picture. You may need to adjust the rear to remove the bolt and take tension off the joint.
You should now have an empty gap
http://i515.photobucket.com/albums/t358/focus550/IMG-20120813-00046.jpg
Now the shock is out the way, remove the monoshock link form the frame, you need to remove the side stand safety switch (2 10mm bolts, tilt the switch towards front of bike and then lower). The nut and bolt is again 14mm & 17mm nut. There is a washer located either side of the linkage between the frame, do not lose these! With the linkage free inspect the bearings for play and condition, re grease if necessary. Remove the dog bones from the swingarm and check the bearings in the swingarm mount, again regrease if necessary.
Also check the bolts and spacers/sleeves for wear and play. Put them through the bearings in which they live and make sure there is no/minimal movement.
clean up and then place the relevant sleeves back into the bearings in which they came from.
Clean up and grease bolts ready for assembly.
Now with the battery tray you need to cut the from left hand corner. Not completely off, just an inch upwards, inch backwards and half way across to the centre (there is a light moulding line)
http://i515.photobucket.com/albums/t358/focus550/IMG-20120814-00050.jpg
http://i515.photobucket.com/albums/t358/focus550/IMG-20120814-00051.jpg
I have installed a layer of foam beneath the battery to raise it up. This ensures it is clear of the reservoir and it is not pincered between the lower of the seat and the battery box/shock reservoir. Check your clearence on the underneath of the seat. Remember when you are sat on the seat it will sit slightly lower. I will get pictures of my set up shortly.
This is enough room for the reservoir to 'fit' inside the battery box. To test the gap is big enough, relocate the undertray/battery box and install the upper bolt of the shock. Trim more off if necessary.
You may need to get a new lower bolt for the shock. I had to get a new nut and bolt. Remember they MUST clear inbetween the dog legs, there is not much of a gap either side. I ordered a new nut and bolt from Suzuki. The bolt must have a high shear stregth as the force is pushing laterally on the bolt.
BOLTS ARE INSERTED FROM THE LEFT HAND SIDE OF THE BIKE
In order to install the new shock, put the bolt through the top mount to suspend the shock. Then bolt the monoshock linkage to the frame (not forgetting the washers). Line up the lower shock to be bolted on to the linkage. Remember to have it facing the right way if you have a rebound adjuster. Now line up the dog legs-it is easier to locate the top bolt 1st, then the lower. Again, you may need to adjust the height of the swingarm to locate the bolts into the holes. When All bolts are in and lined up, you can start to do them up. Remember to torque them up correctly! They do not need to be graunched up. Once all bolts/nuts are done up. Check for free play. Lower the rear of the bike so there is weight on the wheel. Lift up the rear of the bike, check for knocking in the joints/bolts. Push down and do the same.
When you are happy, start to put the bike back together. Take it slow with a new shock on, and adjust as necessary on the next few ride outs.
I have probably missed a few things out, or not explained them properly. If so please tell me and i will edit it accordingly.