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Я - Ребен&#108
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Installing Ohlins shockon a 2004 ZX10R…..

Most modern sport bikes rear shocks are installed and removed the same way. This is a general way to change your rear shock. One person can do this, but two will make the job faster and easier. This should work on most modern sport bikes.



Basic equipment needed are: Front and rear stands, two car jack stands, and a solid 7/16th rode. The rod might be the hardest thing to find. I took a brace off my dining room table, hack sawed it and grinded the ends down (to lazy to go to Home Depot). I found out from my zx10R forum member (Ground Zero) that Lowes sell 7/16th rods and you could buy nylon bushings and nuts to secure the rods.




First: set up the front and rear stands as normal, unfasten the lower cowling to access the rear shock lower bolts.



While the bike is up on the stand loosen all the bolts. On the zx-10 there are 3 at the bottom and 1 at the top.



Now comes the fun part. Take the rod and slide it thru the swing arm hollow bolt. Set a floor jack under the bike and lift it high enough so that you can place both jack stands on both sides of the steel rod. Lower the floor jack so that the rod is sitting center of the jack stands. Make sure bike is secure. Most if not all modern 600/750/1000 and larger sport bikes have hollow swing arm bolts so you may use this technique



Here is a better picture taken from Ground Zero on the zx10R board



if you use the screw rod then you can secure it better than just having a straight rod running through it.



While keeping some force on the rear swing arm with the rear stand, remove all the bolts to the shock. I started with the top bolt. Remove the entire lower bracket that holds the shock in place. The stock shock normally comes out through the bottom. You may have to raise the rear stands higher or get someone to lift on the swing arm in order to get the shock to drop out.



Quick and relatively simple removal…

Stock shock dropping from the bottom.









Installing New Ohlins shock:
Ohlin’s shocks normally goes in from the top (others like Pensky triple clicker can go up from the bottom like a stock shock.



Lower the swing arm by dropping the rear stand. Once drop slide the Ohlin’s in from the top. Line up and slide over brace then insert the top bolt and nut. Hand tighten nut.



Line up and slide over brace then insert the top bolt and nut. Hand tighten nut.



On the bottom install shock brace to swing arm. Next install the dog bones to swing arm.



You may have to use a floor jack in order to get the bottom of the shock to line up with the bracket. Once up slide the bolt and nut on and hand tighten.



Tighten a bit more with a wrench, and then set the bike on the floor for final torque/tightening.



That is pretty much it. Fasten the lower cowling back on remove the stands and make sure all bolts are tight.

I/you still have to get the new shock sag set and then all the fine tuning once you hit the streets! I can't wait to test this thing out.



 

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Hey von, not to highjack your thread bro, but I put the Elka on my 04 and man is this thing awesome. Probably the single biggest upgrade I did to my bike was put this shock on, as the bike is so much better now, and I have a great deal more confidence in the whole bike now.
 

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Я - Ребен&#108
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Discussion Starter #6
1bad7 said:
Hey von, not to highjack your thread bro, but I put the Elka on my 04 and man is this thing awesome. Probably the single biggest upgrade I did to my bike was put this shock on, as the bike is so much better now, and I have a great deal more confidence in the whole bike now.
Thanks guys (you can tell its getting cold) im posting more and more and doing modes since it cold and raining a lot. I actually have a archive of How to's (i always take pics), but sometimes if I don't write these right after i get a lil mind numb! lol and this is like writing a short story lol....

With the bordom of winter coming Ill post my older stuff and i have some more stuff to add..


PS: I can't wait to test this thing! I've heard a lot of people talk about how this is one of the best mods you can do for your bike! Well its raining here for the next 3 days so I'll get out and test and tune asap!!


PS2: LOL, I knew someone was going to get me for the rusty chain, lol Thats from the rainy trip to Bike Week in Ocean City MD a few weeks ago. Didn't even notice it untill i did this mod.

I have some how to's on my 636 (installing forks) and im about to fix a dent in the tank, install some shark skins, and shock and dampner.

I will keep it zx10R stuff here though...

Thanks again fellas and a real Big thanks to Ground Zero for the technique and pic.
 

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Hey Von, there is a tube going from the engine area to the shock and connected to maybe a banjo bolt? what is that for or do?
 

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RR3, I think the tube you are talking about is the hose that goes from the remote preload adjuster to the shock itself. The pic just makes it look like it comes from the engine.

Ohlins for a bike that rarely gets leaned over?:dontknow:
 

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Я - Ребен&#108
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Discussion Starter #9
I think your talking, about the hose to the reservouir (SP). Its attached to the shock and goes to the dial.
 

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Я - Ребен&#108
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phastone said:
RR3, I think the tube you are talking about is the hose that goes from the remote preload adjuster to the shock itself. The pic just makes it look like it comes from the engine.

Ohlins for a bike that rarely gets leaned over?:dontknow:
Awwww why you have to go there? lol
First: you know the strips are only going to show how far over youve been the last time it was out. Trust me when I say i can run this puppy clean past the edge of the tires.

Second: I'm 250lbs geared up and keep this gurl in the upper atmospher as far as how i ride her.

Three: Like most on here know I had 2 zx10R's one for the street and one for the track. Well I got Fucked on the track one as far as getting the motor rebuild, so i just sold it a few weeks ago and brought a 05 636 as my dedicated track bike and the zxten will be my big track bike (road atlanta, VIR north, Barber). The parts i ordered in April when i still had two bike are just coming in. I'm still waiting on my 1.0 springs to come in. So its going on the street ten now.

But I know your just busting my ballz! lol Hmmm lets see your strips?
 

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I would like to try the install. Could you please send me your ohlins rear shock so I can try, Pleeeaase.
 

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Just installed the same Ohlins shock on my buddies and my own bike last night. Followed Vons instructions step by step. 1 hour later, I was done with both bikes! Thanks Von! :eek:ccasion1
 

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Cool thanks good job
 

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setting sag

adding this to this tread b/c i figure the answers will help future installers (and me this time I hope!).

I'm installing my penske tonight. Any tips on measuring and setting sag w/o having a second person to help? What static and weighted sag numbers should I be looking for?

THNX
 

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miykl said:
adding this to this tread b/c i figure the answers will help future installers (and me this time I hope!).

I'm installing my penske tonight. Any tips on measuring and setting sag w/o having a second person to help? What static and weighted sag numbers should I be looking for?

THNX
Miykl if your able to get the rear off the floor and unweighted (and stable) you can get the unladen sag # from axle center straight up to a fixed point on bodywork / subframe or wherever ya can and 'mark' it so it can be used again for both static & rider sag. Now lower it to the floor under its own weight and perform a nice balance job and remeasure from axle center to your 'marked' spot again and see what the diff is from unladen, you'll want 5-6mm of static sag. Without help you'll find it hard to get a proper rider sag # so don't rush it until you do. Once you do have 1 or 2 people to assist try 28-30mm of rider sag (fully suited)

BD
 
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