rear shock change

5 if the bolts are corroded and rounded off ....

[Nobbylad]

Swapping the shock itself takes around 25 mins, I just swapped the bottom bolt around on mine tonight (I'd put the nut on the rhs instead of the near side, so it was rubbing against the dogbones). Took me about 10 mins, including getting the tools/paddock/axle stands out and putting everything away again.

The bugger for me was the battery box. As Ralph said, you can cut this in situ, however I wanted to take my time over it as it was the 1st time I'd done it.

Originally Posted by Nobbylad

Battery box has been trimmed etc and I'll need to get a smaller profile battery (think Neeja got one didn't he?).

Did you have any thoughts on the battery issue? I'm about to start fitting a ZX6 shock to my K4 and I'm wondering what to do about the battery as I've worked out I'll need to hack a fair amount of the battery box away.

[Nobbylad]

I haven't bought a thinner battery yet. The stock battery does fit, but the shock reservoir touches it (not sure if over time it will wear as the shock moves). It was tight against the underside of the riders seat, however it has moved down a few mm now so the seat just clears it.

Not sure what it would be like with the ZX6 shock, although a few on here have used that one.

I have a zx10r shock.



My toolkit now lives under the pillion seat and I went to B&Q and got a block of polystyrene and cut it to the shape of the toolkit holder, plus a bit longer, so it sits in the toolbox holder and protudes into the battery box. The standard battery sits on top of this and is about 3-4mm clear of the shock reservoir. Cut the foam blocks off the bottom of the riders seat, and it clears the top of the battery by another 3-4mm.

[CSpronken]

I recently installed a '03-04 ZX6RR rear shock (external reservoir) on my curvy. To fit the original battery I would have had to bend down the original undertray about 2 inches. Since I was also installing a powerbronze undertray and didn't fancy the look of the undertray bended down so much, I decided to buy a li-ion battery at Durbahn.de. I've now installed this battery and after cutting the batterybox (already had to mess up the orginal undertail any way to add the new one) I had several mm clearance between the new smaller battery and the reservoir with only 2 washers between the undertail and the subframe. One or none would probably have been enough as well, just wanted to be on the safe side.

The Li-ion battery saved me 2 kg in the process (battery weighs about 700gr) and I could reinstall the relay and fuse box section without any modification needed. It's recommended to balanced the cells in these Li-ion batteries once and a while. If you're gonna do this it might be a good idea to extend the charging cables to the pillion seat and make a plug to make the job easier.

Because the bolt of the SV shock screws into the shock fork while the ZX6RR shock has an external nut I did have to remove quite some metal from the bolt and nut I got with the ZX6RR shock in order to keep it clear from the dogbones also with the play in the assembly, but felt it there was still enough left for a safe fixation.

The original shock felt soft and harsh at the same time (soft on long bumps harsh on short ones), the ZX6RR shock is better suited for my weight (82 kg), feeling firmer but not overly so, yet smoother on short bumps. Furthermore I now have bump and rebound damping control although the settings I guestimated (pre-load and damping a notch up from standard Kawasaki settings) seem to work fine so far. The rear height doesn't seem to have risen much, despite the longer spec length 340 vs. 337mm.

[yorkie_chris]

Which pack did you get from Durbahn?

Maviryk on svrider sells those packs a little cheaper I think.

[CSpronken]

Originally Posted by yorkie_chris

Which pack did you get from Durbahn?

Maviryk on svrider sells those packs a little cheaper I think.

Yeah I know, but with shipping cost and all I figured I get them closer to home (Dutchy here).

http://shop.durbahn.de/shop/en/products/Batteries_superlight_!/_A123_LiFePower-Durbahn

A123 LiFePower-Durbahn
A123 LiFePower Pack 4.6 Ah (8-cell)

There a 2 x 2 harness cables (2 for plus and 2 for minus) which can be fused into 2 supplied connectors, 2 charge cables plus a balancer cable/connector. You can list the desired cable length when ordering. The Maviryk packs have a handy plug already installed, not sure how they are externally charged and if there is a balancing cable/connector. Maviryk says it isn't needed, but I will be balancing my Durbahn pack now and then. I bought a Hyperion EOS0606i charger at a local webshop for 79 euro: http://www.rctechnics.eu/hyperion-06...er-p-2331.html

Fitting a 2004 ZX10R shock with no cutting or moving of stuff I just fitted spacers to the battery box mounting to keep it out of the way of the reservoir

ive read somewhere about foam for the battery..... and read polystyrene aswell -- will this be ok or not? gonna have a bash this weekend i think... hopefully all goes well.