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Old January 28th, 2015, 06:36 PM   #1
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Gixxer shock on a pregen (with pics)

There are probably as many different ways to do this project as there are people that have done it, here's how I did it.

to start with the stock shock is 12.5" c to c
as you can see I've added a preload spacer about 3/4" thick under the stock spring
DSCF0025.jpg


GSX-R shock is also 12.5" c to c (might be 1/16" under)
DSCF0026.jpg


first I drilled out the eyelets to 15/32" to fit the stock Ninja bolts
DSCF0001.jpg
DSCF0002.jpg


then we have to grind or file or machine the bottom clevis on the inside to fit the lower Ninja bushing from the suspension linkage
DSCF0012.jpg


I chose to use the grinder, be careful to not take out too much material or the aluminum clevis will bend or break when you tighten the lower linkage bolt
DSCF0014.jpg
DSCF0013.jpg


the upper shock mount bracket interferes with the Gixxer shock where the front of the rear fender bolts up
DSCF0015.jpg


so away with it (the bracket), I used a sawzall with a metal cutting blade
DSCF0016.jpg


aaauh, fits much better
DSCF0019.jpg


now I cut the battery box off of the air box (I used a hand hacksaw)to move it up about an inch
DSCF0005.jpg


I used a couple of sheet rock screws to reattach the battery box
DSCF0009.jpg


then I cut the front of the rear fender
DSCF0020.jpg


to slide it under the battery box and reattach it with the 2 bolts in the bottom of the battery box
DSCF0021.jpg


have to drill a new hole in the overflow mounting tab as the rear fender gets relocated a little
DSCF0023.jpg

Put you plastics back on and your ready to go. Static height is 1/4" lower as the stock shock with the spacer did not sag under it's own weight, however the sag (with rider) ended up the same (about 1.25"). I used the stock Gixxer spring and all the stock Ninja linkage and bones.
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Old January 28th, 2015, 08:30 PM   #2
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Cool



Great pics !!!
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Old January 28th, 2015, 09:14 PM   #3
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Thanks this answered many questions I had.
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Old January 28th, 2015, 09:50 PM   #4
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Old January 30th, 2015, 11:03 AM   #5
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Great, simple write up. The pics are very helpful - especially the one that depicts where to grind for the lower shock mount spacer.

Did you need to shim your dog bones, to space them out a little bit? I have read where others state that they catch on the the shock spring.
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Old January 30th, 2015, 04:04 PM   #6
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Quote:
Originally Posted by spent_too_much View Post
Did you need to shim your dog bones, to space them out a little bit? I have read where others state that they catch on the the shock spring.
I've done it to this one (a 2000) and an 02 without a problem, it's close but a miss is as good as a mile.

Maybe they had a different year shock or something I can't even tell you for sure what year these are as my son just picked them up off ebay, but I've got 3 of them and they're all the same.
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Old February 5th, 2015, 06:48 PM   #7
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2009 is the year of shocks. I think 08 was the same shock. 07 and older have the resevior up higher which runs more interference with mounting it. The 09's have the pretty blue anodizing on them. ha ha ha.
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Old February 5th, 2015, 07:01 PM   #8
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Old February 7th, 2015, 04:44 PM   #9
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For whatever it's worth, Racetech's calculator breaks them down into '01-'03, '04-'05, and '06-'09. They're listed as having 450#, 425#, and 525# spring rates respectively. For comparison, the PreGen is 440# and the NewGen is 520#.

Just browsing some eBay pics, it looks like the '06-'07 ones have the reservoir sticking pretty much straight out, like the '08-'09 ones, as pictured in the first post. The '04-'05 and '01-'03 ones both have it angling up quite a bit.
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Old February 11th, 2015, 09:12 AM   #10
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Quote:
Originally Posted by InvisiBill View Post
For whatever it's worth, Racetech's calculator breaks them down into '01-'03, '04-'05, and '06-'09. They're listed as having 450#, 425#, and 525# spring rates respectively. For comparison, the PreGen is 440# and the NewGen is 520#.

Just browsing some eBay pics, it looks like the '06-'07 ones have the reservoir sticking pretty much straight out, like the '08-'09 ones, as pictured in the first post. The '04-'05 and '01-'03 ones both have it angling up quite a bit.
yes, I have an 05 gxsr 600 shock and the reservoir sits pretty hi...
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Old July 8th, 2019, 11:16 PM   #11
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Updating this DIY guide to simplify and make it even easier to do. For those wishing to install GSX-R shocks on Ninjette, there is no need to drill out upper shock bushing or your frame mounts. The 10mm bolt used for GSX-R shock is fine because it generates sufficient friction to hold bushing in between ears.

To use factory unmolested 12mm mounting ears and 10mm shock eyelet, you just need two sleeves like this. Might need to remove 1mm from width to not extend beyond width of mounting ears on frame. These fill up larger hole in frame mounting ears and allows simple bolt-on use of GSX-R 10mm bolt.

Polaris # 5135275 - https://www.ebay.com/itm/302898035590

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Old December 26th, 2019, 12:39 PM   #12
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Would it also work if you were to grind down the bushing instead of the lower clevis?
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Old December 26th, 2019, 03:32 PM   #13
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Above instructions for top-mount of shock. Yes for bottom mount you can do:

1. narrow bushing on knuckle to width of shock clevis

2. use bushing-inside-of-bushing to fit shock clevis to factory bushing. Should be 12.7mm OD and 10mm ID. Just wide enough to tightly fit tightly inside clevis and factory bushing. This sleeve should fit inside factory bushing. Ream ID out to 10mm with length for tight fit on clevis on shock (slightly narrower than narrowed factory bushing so all clamping-pressure goes onto knuckle bushing).

This sleeve radially locates and centre GSX-R 10mm bolt inside of factory knuckle bushing once that's been narrowed to fit inside shock clevis. Lateral location is provided by narrowed factory knuckle bushing. Once bolt is fitted with minimal play, tightening it locks everything in place. Rotation is done by factory bushing inside of knuckle.

https://www.zoro.com/bunting-bearing...12/i/G4189586/

No hacking frame needed!

Last futzed with by DannoXYZ; December 26th, 2019 at 10:02 PM.
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Old December 26th, 2019, 05:43 PM   #14
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Cool, thank Danno
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Old December 30th, 2019, 08:28 PM   #15
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I need to take apart rear-suspension and confirm knuckle-bushing has enough extra-width to grind down to fit inside GSX-R's shock clevis... Perhaps this weekend...
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Old January 21st, 2020, 02:38 PM   #16
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Quote:
Originally Posted by DannoXYZ View Post
Updating this DIY guide to simplify and make it even easier to do. For those wishing to install GSX-R shocks on Ninjette, there is no need to drill out upper shock bushing or your frame mounts. The 10mm bolt used for GSX-R shock is fine because it generates sufficient friction to hold bushing in between ears.

To use factory unmolested 12mm mounting ears and 10mm shock eyelet, you just need two sleeves like this. Might need to remove 1mm from width to not extend beyond width of mounting ears on frame. These fill up larger hole in frame mounting ears and allows simple bolt-on use of GSX-R 10mm bolt.

Polaris # 5135275 - https://www.ebay.com/itm/302898035590

Just took apart my pre gen for swing arm service and found that the nut for the upper shock mount is actually welded to the frame so most likely you would need to drill out the eyelet of the shock.
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Old February 24th, 2020, 12:56 PM   #17
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Quote:
Originally Posted by Ceeloo Yello View Post
Would it also work if you were to grind down the bushing instead of the lower clevis?
To answer my own question - the answer is no, the uni trak is also too wide.
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Old June 11th, 2020, 02:13 PM   #18
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Finally got my gixxer shock installed thanks to this great write up.
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