Fitting a ZX636 shock - what will I need?

[dyzio]

Hi,
Since upgrading the front has made such a big difference, I've bought a rear ZX6 shock.
I know about cutting the battery box, but what else do I need and where do I get it?
Think I need a bolt from a kwak (Bolt - 10x55 part # 09103-10143, nut - part # 08319-31107)??
Any lubes? locktite?
Help!

Cheers

Well its best to grease all the bearings when you have it apart. Now the only other thing is getting the shock 'fork' threaded to take the bolt as its not like the SV one with a thread. I had a mate who got it helicoiled.

[dyzio]

Which bearings and what thread size are we talking about?

The tri-linkage bearings, which attach the shock via the linkage to the swingarm.

You don't need to helicoil the bottom of the shock you can use a longer bolt, just turn it around, the clearance between the dog bones is not the same on both sides.

The thread size is M10 fine.

And I'd threadlock all the bolts.

[dyzio]

Originally Posted by mattc

You don't need to helicoil the bottom of the shock you can use a longer bolt,

like this or longer?
Bolt - 10x55 part # 09103-10143

I got the kwak bolt when I fitted mine - can't remember the part number but its the one from the bottom of the shock on the 636bh1. Unfortunately its still too long and fouls the dogbones so be prepared to take a hacksaw to it to cut it down to size. Do it right and it fits fine.

In addition you will need to chop off the bottom of the battery box and also the metal section from the tank hinge which holds the battery in place as it fouls the reservoir of the 636 shock.

Well worth doing though - makes a huge difference to the handling.

[mister c]

I should be getting mine shortly. I will do a photo "How to" when I do it

[dyzio]

Originally Posted by mister c

I should be getting mine shortly. I will do a photo "How to" when I do it

Somebody, get him a pint!

Originally Posted by Spoon

I got the kwak bolt when I fitted mine - can't remember the part number but its the one from the bottom of the shock on the 636bh1. Unfortunately its still too long and fouls the dogbones so be prepared to take a hacksaw to it to cut it down to size. Do it right and it fits fine.

In addition you will need to chop off the bottom of the battery box and also the metal section from the tank hinge which holds the battery in place as it fouls the reservoir of the 636 shock.

Well worth doing though - makes a huge difference to the handling.

Yeah, definitely need to modify the tank hinge and cut the bottom battery housing.
The battery needs to sit higher so you have to relocate the fuse tray as well, you can fit this under your modified tank hinge.

This is how i did it lift bike up so swing arm is free.




Take off rear wheel (slacken chain adjusters, brake torque arm then undo and remove the axle and at the same time take out the rear wheel)




Remove the side grills and take off the rider seat.


Remove the linkage bolt attaching the swing arm, if your unlucky like me it wont budge even with air tools and will need to be cut. Send dad out to Smiddy to get bolt with the bits of the old one.






Undo top and bottom shock bolts and take out old shock.




Remove old shock and place old by new side by side.


Remove the battery and take all the wires out the way.


Squeeze zx10r shock up very fiddly but by moving swing arm up/down as well eventually get close look how much battery box needs to be cut. A lot in my case sorry no pic might get one but will need to take of seat etc again and im spraying in the garage at the minute.


Cut battery box i used an air saw others have used dremmels just use what you can. Offer shock up again cut more off battery box and repeat until the Zx10 shock would fit.


Attach bottom shock bolt i used a high tensile M10 by 55 i think again from local smiddy. However this still had to be cut slightly shorter and the bolt put in from the other way round to give more clearance.


I reused one of the Sv bolts for the top shock bolt.




Start putting things back together bin the fuse box.