Sport Bikes banner

1 - 9 of 9 Posts

·
Registered
Joined
·
215 Posts
Discussion Starter · #1 ·
The nut and cotter pin on top of the rear shock looks like a PITA to remove. Would raising the rear of the gas tank help or do you have to remove the plastic panel under the seat too? Wouldn't it be easier to find or fabricate a spacer with a U-shaped cut out? All that would have to be done is to loosen the nut enough and slide the new spacer in and re tighten the nut.
 

·
Premium Member
Joined
·
5,547 Posts
I used the 12mm spacer that I told you about, after reinstalling the top shock mount into the frame, it was a pain in the ass to get a new cotter pin installed so I used a clip pin, I also had my next door neighbor's five year old with really small hands help me out with reinstalling the clip pin. Also you see a spring installed on the Ohlins shock, when I purchased the shock last winter the red spring which is an Eibach spring was installed, the shock also came with original yellow Ohlins spring which was much longer by about the height of 1 1/2 coils. Last May when I was at Wheelers Performance in Robbinsville, NC Ken said I needed to go with the longer spring so he could set the bike up to my weight again after the Ohlins shock swap and the fork revamp.
 

Attachments

·
Registered
Joined
·
215 Posts
Discussion Starter · #3 ·
Jay Did you raise the rear of tank? Where do you get those pins? Did the ZX 10R suspension links raise, lower or keep the rear of your bike at the same height. I am trying to find out if the 12mm spacer is the correct one to use. Here is the main questions: How much does raising the rear of the bike 3/4'' change the steering geometry. What would be the old rake and trail as opposed to the new rake and trail? How does one know what the optimum steering geometry would be?
 

·
Premium Member
Joined
·
5,547 Posts
Jay Did you raise the rear of tank? Where do you get those pins? Did the ZX 10R suspension links raise, lower or keep the rear of your bike at the same height. I am trying to find out if the 12mm spacer is the correct one to use. Here is the main questions: How much does raising the rear of the bike 3/4'' change the steering geometry. What would be the old rake and trail as opposed to the new rake and trail? How does one know what the optimum steering geometry would be?
Yes, I had the entire tank off the bike. I picked up the pin at my local small town hardware store right around the corner from my house. I also have a larger version of that pin that replaced the cotter pin on my rear axle. Cotter pins are a pain in the butt. The 04/05 ZX10R dog bones are the exact same length as the ZZR600 dog bones. I went with 04/05 ZX10R suspension knuckle because its not as wide as the ZZR600 suspension knuckle. The Ohlins shock that I have is for a 04/05 ZX10R. Which one of the many interchangeable/swappable parts. The Ohlins shock is longer than the stock ZZR600 shock thus raising the rear end in the air. I really like the way the bike feels now as I tip into a curve versus with the stock rear shock.

There is a guy that posts on here that is very knowledgeable with that subject, his screen name is "riverzzr", he works on bikes for a living and is a pool of knowledge.

Here's some info that you may find helpful, not sure if you have ever seen this or not.

*MASTER SWAPPABLE PARTS LIST*

Now some basic information regarding the bikes covered.
98/99 ZX6R "G" Model
00-02 ZX6R "J" Model
05-08 ZZR600

Now, for the most part, here are the differences comparing the "G" to "J" Model bikes.
-Upper Fairing only had 1 headlight, used different windscreen, and air ducts, but the entire rest of the bodywork will swap out.
-Used a different gauge that is wired differently.
-Gauge stay/ Fairing stay was different and not swappable
-Swing arm is the same, just the "J" Model had a "Knife Edge"
-98-99 forks were spaced about 3/16" narrower than 00-02 and were 1 1/4" longer for over-the-clamp handle bars.
Fender mounting is slightly different, but you can go either direction with some minor modifications to the fender.
Brake calipers will bolt up (virtually any ZX caliper will fit except the radial mount style) , supposedly the 00-02 had less fade.
-Front Fenders were slightly different.
-Charging system was different, as was the ignition system, so for people looking to do a engine swap, either will work, but you must use your existing pickup rotor, stator, and harness including coils.
-The "bottom end" of the engine was the same, but from the cylinders up the engine was different internally.
-The gas cap had 5 bolts instead of 3
-Steering Head Bearings were tapered roller (timpkin) instead of the roller ball bearings used on the newer ones, either can be used with the correct races.

Now to compare the "J" Model to the ZZR600
-Simply put, the ONLY difference was the fairing stay, and it eliminated the "bird cage", and can be used on the "J" Model, it will work on the "G" model as well, but only if you have the "J" Model Headlights and upper as the headlight mount is different and the overall shape of the upper is different.

So to put all this in simple terms, the 00-02 ZX6R "J" is IDENTICAL to the 05-08 ZZR600 with the exception of the fairing stay which can be used, so ANY PART FOR THE 05-08 ZZR600 WILL FIT THE 00-02 ZX6R "J" AND VICE VERSA!

Now for a little more info regarding other bikes.
-05-10 ZX6R Wheels are all the same
-98-04 ZX6R Rear Wheels the same
-05-10 ZX6R Front Rotors are all the same
-98-10 ZX6R Rear Rotors are all the same size and bolt pattern, they just went to a "Wave" rotor in 2005
-98-10 ZX6R Front Sprockets are the same CHECK PITCH 2003 went to 520!
-98-10 ZX6R Sprockets all have the same bolt pattern, 2003 they went to 520 from 525
-98-04 ZX6R Mirrors are the same stud spacing
-05-10 ZX6R Mirrors have the same stud spacing
-05-08 ZX6R Swing arms are the same, in 07 they changed the look slightly, but still the same bolt spacing and sizing.
-03-08 ZX6R Clip-ons are all 50MM and work with each other.
-03-06 ZX6R Top Triple Clamps are the same just look different
-03-08 ZX6R Forks the same dimensions are the same, just 03/04 had smaller rotors so the caliper mounts were 10MM shorter.
-03-10 ZX6R Calipers all bolt up, 03-06 ZX6R Exactly the same 07-10 ZX6R went to Nissins which are a much better caliper.
-98-10 ZX6R Bar Ends all the same
-00-10 ZX6R Gas Caps interchangeable
-06-10 ZX10R Front Wheel same as 05+ ZX6R
-04-10 ZX10R Rotors the same as 05+ ZX6R
-98-03 ZX9R Rear Rotor same as the ZX10R/ZX6R
-98-04 ZX6R Passenger Pegs the same
-05-10 ZX6R Passenger pegs the same
-98-10 ZX6R and ZX10R Rear Calipers are all the same
-98-10 ZX6R Cush Drives are the same piece
-98/99 ZX9R Front Rotors are he same as he "G" and "J" and ZZR600


Now for the Parts Swapping Information!

Wheels,

-03/04 ZX6R Rear Wheel is a direct bolt on, the front wheel needs the 05+ ZX6R rotors to be used. Always use the spacers for the generation wheel you are swapping for a direct swap.
-05+ ZX6R Rear Wheel can be used, but is skinnier and needs either new spacers made or spacers added to what is there, the front wheel is a direct swap, but the newer rotors are needed as well.
-06+ ZX10R Front Wheel is the same situation as the newer ZX6R.
-00-02 ZX9R Wheels fit, but the rear is 6" instead of 5.5" and will need spacers made and the chain lined up, but the front is a direct swap.


Swing arms,
-03/04 ZX6R Swing arm is the same as the 98-02 in size, but it has an extra tab or two for more Hugger Choices.
-05-08 ZX6R Swing arm bolts on, but the corresponding wheel needs to be used for it to be direct bolt on, also a longer chain and brake line is needed.
-02/03 ZX9R Braced Swing arm will bolt on with minor machining overall width and bearing swap out. Luxeryliquidator knows the details, PM him for details. not as easy as the 636 swap, but different!
-09/10 ZX6R Swing arm, i have not swapped or seen it done, but i had heard of people doing it on the 05+ bikes, and if it can be done on them, it can be done on ours just as easy, and it seems like a simple swap for the most part, but no definite information on it yet.


Shocks,

-03/04 ZX6R Shock is a direct swap, slightly better then the 98-02 shock.
-05-08 ZX6R Shock will bolt up with either grinding of the lower mount of the shock, or swapping over to the corresponding linkage.
-04+ ZX10R Shock is the same deal as the 05+ ZX6R.


Forks,

-03-08 ZX6R Forks can be swapped onto the bike, but here are a few things needed to be done,
Press the Steering Stem from the stock clamp out and then into the 03-08 ZX6R Lower Clamp
Then a Bushing will need to be made to go into the Top Clamp and fit around the 98-02 Stem, this will prevent twisting of the front end.
The Top Clamp will need to be trimmed down in the Ignition Switch area for the original switch to be used, and you will lose the function of the steering lock at full wheel turn
With the swap you can use your stock wheel and spacers, but you must use your stock rotors as well due to backspacing of them.
You will also need to drill new holes in the new clip-ons for the locking pins for the throttle housing.
03-04 front forks and triple trees
-09-10 ZX6R Forks should be the same deal, i have yet to try it but it should be, but in 2009 they went to 51MM forks, so the correct clamps need to be had.
-04-10 ZX10R Forks also should be the same thing except the 2004/05 ZX10R Front axle is smaller, so the correct wheel is needed.
-ZX12R front end will bolt up with the only mods being, omitting a top locknut(which the top triple clamp holds tight) a simple bolt-on, with gains of inverted forks/tighter springs/oversized brakes.


Exhaust,

-03/04 ZX6R Header will bolt up, either aftermarket or stock. Doing this will open a wide variety of slip-on options including high mount pipes!
-98+ ZX9R Bolt on Cans will fit right up the ZX6R


Engine,

-03/04 ZX6R Engine will bolt into the frame with the exception of the front 2 engine mounts, which are critical, but with some welding and fab it can be done, i have done it. Remember if you do decide to do this, you will need all the electronics off of the bike along with the tank and fuel pump, and you will need to make the tank fit as the mounts are quite different, but does line up decent.
-03/04 ZX6R Clutch Cover and Ignition Cover bolt on.
-03-06 ZX6R Radiator will bolt up and the hoses line up great, the 05/06 ZX6R does not have a fan switch built in, and they are physically smaller then the original, but work fine, especially for fairing swap when you need a smaller one.
-03-06 ZX6R Pistons fit, the "RR" Pistons are forged and 1MM smaller then the "636" Pistons. Use the 98/99 ZX6R "G" Cylinders, and bore them sense they are steel, and have a cheap Big Bore Kit, The 98/99 Head cant be used though, the engine needs a 00-02 Zx6R "J" Model head, or 05-08 ZZR600.
-98-02 ZX6R Cams interchange, they were different, but can be swapped, some believe there is a performance gain in using the "G" Exhaust cam.
-98-02 ZX6R and 05-08 ZZR600 Carbs can be swapped with minor jetting changes throughout the years, but they will bolt on no issue.
-91-95 ZX7R carbs can bolt on, with some tinkering. Rerouting the throttle cables, with an inversion of the twist assembly.Using larger clamps, heavy modifying the carb plate and a lot of patients doing the jetting unless you have access to a really good engine brake dyno, with fans for ram air replication!

Master Parts Swap List Ver2.0 98+ ZX6R : KawiForums.com Kawasaki Forums: Kawasaki motorcycle forums
 

Attachments

·
Registered
Joined
·
215 Posts
Discussion Starter · #5 ·
How much higher did the Ohlins rear shock and spacer raise the tail of your bike? Did or does your bike need a steering damper after changing the front end geometry?
 

·
Premium Member
Joined
·
5,547 Posts
How much higher did the Ohlins rear shock and spacer raise the tail of your bike? Did or does your bike need a steering damper after changing the front end geometry?
I was able to increase the rear ride height from 19 1/2 inches to 20 1/4 inches. 3/4's of an inch doesn't sound like much, but oh what a difference in the corners. That measurement is from the center of the axle to the center of the key hole on the rear tail plastic. IMO a steering damper isn't really needed on this bike, before or after all of the suspension work I have done.
 

·
Registered
Joined
·
215 Posts
Discussion Starter · #7 ·
This week I installed new front and rear spring(s) plus new Michelin Pilot Power3 tires . Trailered the bike to Eagles Canyon Raceway where P1 Racing set up the suspension. Next week it's off to Marble Falls Arkansas to get some riding in.
 

·
Premium Member
Joined
·
5,547 Posts
Glad to hear you got her set up. Marble Falls looks like a neat place. Do you still want that 12mm spacer? I can bring to the Gap if you would like.
 

·
Registered
Joined
·
215 Posts
Discussion Starter · #9 ·
Jay, I wasn't sure you were going to get the spacer. If you have already purchased it, I will reinburse you for it. I added a second OEM spacer last week. BTW, there was a really good three day event going on at Eagles Canyon Raceway.
 
1 - 9 of 9 Posts
Top