March 19th, 2016, 08:48 PM
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#19
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ninjette.org guru
Name: Mike
Location: NJ
Join Date: Jul 2014
Motorcycle(s): 2014 Ninja 300 track bike, 2007 Suzuki GSXR 750 track bike, 2002 Yamaha R6, 1995 CBR600RR f3 track bike
Posts: 304
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GSXR Shock Install
Pics of the GSXR shock install. It took me about two hours. All of the nuts, bolts and washers were purchased at Lowe's. The bolts are M12-1.75x120. The nuts are nylock style.
Pic 1: The 2006-2007 GSXR 600/750 shock. Remove the top mount if it's still mounted. You must drill out the top and bottom mounting holes of the shock using either a 12mm or 15/32" bit.
Pic 2: These are the tools that I used to drill the shock, cut the plastic undertail above the shock and to grind away the inner surface of the lower shock mount.
Pic 3: This is a Dewalt 15/32" bit that I got from Lowe's. About $10. Drill the top shock mount hole first while the bit is still new and sharp. Use a lubricant when drilling metal. I had some anti-seize handy so that's what I used. Drill part way through from one side then flip the shock and drill from the other side. Do the same for the bottom. Once you've drilled through run the drill in and out of the holes and wiggle the drill around a little to open the holes up a fraction more especially if you used the 15/32" rather than a 12mm. Test fit your bolts to make sure they slide in easily.
Pic 4: Before you get to the drilling, grinding and pounding put on some gloves and safety glasses. Don't be a dummy.
Pic 5 & 6: The bike set up on stands. The front of my bike is held up by a triple tree stand (not pictured) so it's really steady. The bricks are unnecessary. The jack under the pan is to steady the bike for when you're ready to take out the old shock and put in the new shock. You have to drop the rear tire and swing arm to get the shock in there. To do that you just lift the handle of the rear stand.
Pic 7: Before you do that though you have to remove the frame plugs so you can access the top shock nut/bolt. 17mm bolt, 19mm nut for top and bottom and for the dogbones.
Pic 8: You can get the old shock out pretty easily but to get the GSXR shock with the gas reservoir in you'll need to cut the plastic cover away along the red line. I was able to do it without removing it using a Dremel (rotary tool) with a router-type/Roto-Zip-type bit. It was the worst part of the job because of the mess of plastic debris. It really only took a few minutes.
Pic 9 & 10: Measurement of the lower shock mount arm. This is the dimension that you have to grind the GSXR shock bottom out to.
Pic 11 & 12: The measurements of the lower GSXR shock mount yoke before and after grinding.
More to follow.
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Track, track, track
Last futzed with by Mike K; March 20th, 2016 at 12:17 AM.
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