Shock Swap with 99-02 R6

Formula390

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I rebuilt my R6 shock today. Bit of a PITA to take apart. GP Suspension has new seal heads for $25 or so; certainly worthwhile so you can get away from the double snap ring, multi piece stock seal. I added a little length while I had it apart and made a new schrader cap for the reservoir.

I also found that a spare linkage I had around from a GSXR 600 has the needle bearing sleeve that is the right OD, length, and correct 10mm ID. Turned up some shims and put it in. Probably be a week or two before I get to test it out...

-Sean

You can do it a lot easier if you just grind out the top snap ring groove to easily get the cap out. It does destroy it, but it's much less of a PITA and significantly quicker. You can then use the Racetech (part number SYSH 4014) replacement head w/shrader valve in it already. The new head is then seated under the under where the second circlip resides. Wroks a peach. I was unsure if the bladder and bladder cap were also required, or if that was a different option/method of going about rebuilding as I'm unsure what the bladder/bladder cap in their product listing is in regards to the OEM R6 shock. All the shocks I've rebuilt in the past have had remote reservoirs. This is the first time I've dug into a shock which has the reservoir as part of the actual casting of the top of the shock. It looks like the internals with otherwise be completely familiar. Not like this stuff is complete rocket science. It is, after all... Voodoo! LOL I'm going to try it with the stock valving as a test first to see how it does and determine if rebuild is required in general for all cases, or (hopefully not) if it can be left alone so it's easier for more folks to do as swapping a spring is likely in the realms of possibilities for near everyone and not as difficult for a novice wrench to tackle who might otherwise be put off tearing the shock completely apart. The easier it is to do, the more likely more people will be able to take advantage of the mod.
 

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I also found that a spare linkage I had around from a GSXR 600 has the needle bearing sleeve that is the right OD, length, and correct 10mm ID. Turned up some shims and put it in. Probably be a week or two before I get to test it out...

-Sean

Yeah, please report how that works out. That would likely be easier for folks to do and a better solution for using a PTFE coated bronze busing if a roller bearing can be utilized. Did you have to press out the old sleeve or can that easily be removed by hand? I don't remember as I just dropped a 12mm to 10mm busing bearing in for mine to get to the necessary 10mm ID, and used some machined to size flat washers for my side shims. If it works, and the bottom sleeve comes out easy, then we can find the part number (do you know which model year the gixxer linkage came from?) and add that to the list of parts folks will need to accomplish the swap.
 

RoninJames

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So I am the novice wrench :) I can install the basics, do an oil change, stuff like that. Only real experience w engines is working on 2 strokes a bit. So i am betting i would be a good test of this mod being easy enough for someone w basic wrench turning skills to do this.

I have been following the thread, and messaging w Matt back and forth because this is the biggest issue with these bikes to me and i would love to get it sorted first, and i am on a budget so buying a 1500 dollar shock is not really my ideal.

I ordered a stock R6 shock... and then I got an incredibly good deal on a used Ohlins shock for the 02 R6. So my Ohlins is on the way and i am getting some bushings from matt and gonna mount that sucker soon and report back. The two biggest advantages of the Ohlins i see are ride height adjustment and the threaded preload adjuster. the springs size may differ from the oem shock and i will prob make some calls or email some suspension guys to sort that out too when the time comes.
 

mr-fabricator

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Any progress people ???? My springs front and rear for the r6 shock wont be here for another week or so . And wont hit the track untill middle of august !!! Pah !
 

RoninJames

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Any progress people ???? My springs front and rear for the r6 shock wont be here for another week or so . And wont hit the track untill middle of august !!! Pah !

i got my ohlins R6 shock and it looks good. should have my bushings soon to mount it and see what is what.

i did some research on the spring that comes on the ohlins shock.... there is some debate on the R6 forums... its labelled 1093-29/90 which a few guys say is rated for a rider 150-170lbs.... then a couple guys from a suspension specialist said their racers use that size for up to 200lb riders.

i am 185. the difference between a dry 02 R6 and the RC is 46lbs roughly so im am thinking that if that spring IS for a lighter rider on the R6 then it may be ok for a heavier rider on the RC. again, i am not a suspension guy but i would think the springs are designed for combined weight of bike and rider... so the combination of heavier R6 and lighter rider vs lighter RC and heavier rider should balance out and be close. am i crrect in that thinking? or am i a noob lol
 

SCUBA

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Got my shims from McMaster Carr. PN 6679k15. Get 2. Just waiting on a any input on a race tech spring for a 200lb guy.
 

Formula390

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Got my shims from McMaster Carr. PN 6679k15. Get 2. Just waiting on a any input on a race tech spring for a 200lb guy.

Not to be pedantic, but it's "bushings" not "shims." :) You'll need two of the 15mm, or three of the 10mm. Then you'll have to fabricate up some spacers on the sides (you could use large flat washers) for the sides to take up the rest of the space between the shock sides (and hold the bushings in place) and the swingarm mounts.

So far, it's looking like either the 11.6 or 12.5 is going to be what's needed for us big boys... but I'll see on Thursday when I test out the 11.6 spring from RaceTech and see how it does.
 

mr-fabricator

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i got my ohlins R6 shock and it looks good. should have my bushings soon to mount it and see what is what.

i did some research on the spring that comes on the ohlins shock.... there is some debate on the R6 forums... its labelled 1093-29/90 which a few guys say is rated for a rider 150-170lbs.... then a couple guys from a suspension specialist said their racers use that size for up to 200lb riders.

i am 185. the difference between a dry 02 R6 and the RC is 46lbs roughly so im am thinking that if that spring IS for a lighter rider on the R6 then it may be ok for a heavier rider on the RC. again, i am not a suspension guy but i would think the springs are designed for combined weight of bike and rider... so the combination of heavier R6 and lighter rider vs lighter RC and heavier rider should balance out and be close. am i crrect in that thinking? or am i a noob lol

RC is direct attachment from.swing arm to frame where the r6 is on a link , this can multiply equations so comparing a spring one one bike will be different to another irrespective of bike and rider weight . Stock r6 is around 8.8 iirc but for a rc aplication we need to be north of 11 even for a lightish rider (180lb)
 

Formula390

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RC is direct attachment from.swing arm to frame where the r6 is on a link , this can multiply equations so comparing a spring one one bike will be different to another irrespective of bike and rider weight . Stock r6 is around 8.8 iirc but for a rc aplication we need to be north of 11 even for a lightish rider (180lb)

You Aussies crack me up that you think 180# is "lightish"... :)

Smoke me a kipper, I'll be back for breakfast!
 

RoninJames

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RC is direct attachment from.swing arm to frame where the r6 is on a link , this can multiply equations so comparing a spring one one bike will be different to another irrespective of bike and rider weight . Stock r6 is around 8.8 iirc but for a rc aplication we need to be north of 11 even for a lightish rider (180lb)

damn, yea i forgot about the link on the R6. oh well so much for my theory. i have access to a couple other springs if i need them from a guy who has a 105, 11 and 12
 

mr-fabricator

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Well im 160 lb on the scales + my gear on that , maybe i should have said average :) ha ha .

I ordered a 12.5 can always go down from that but we gotta start somewhere .

Give it 6 months and there will be lots of people with a better idea tried and tested . Its all theory at this point
 

RoninJames

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Hey guys, got all my parts ready to go. Now the fun part... what do you guys use to hold the bike up while swapping the rear shock? Im not a mechanic, dont have a lift or anything like that.
I am thinking if i take the underpan off that the bottom of the engine is flat enough to go on a low mx type stand right? and use a track stand up front to steady the front of the bike?

What all did you have to take off to get at it and get it off.
Obviously the chainguard and hugger have to come off... and i read the exhaust can has to come off as well.
Any chance of getting this shock out without removing the back wheel?
 

mr-fabricator

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I dont run a chain guard anyway but i removed nothing from the bike other than the belly pan , wheel , exhaust etc stayed where they were . I do run a Arrow exhaust so the stock one may be a little tighter

get a buddy / the wife to hold the front of the bike and use a car jack under the engine , they will need to weight the front of the bike slightly . If u have the side stand still u can just pull the bike over on that and the back wheel will come up .
 

RoninJames

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I dont run a chain guard anyway but i removed nothing from the bike other than the belly pan , wheel , exhaust etc stayed where they were . I do run a Arrow exhaust so the stock one may be a little tighter

get a buddy / the wife to hold the front of the bike and use a car jack under the engine , they will need to weight the front of the bike slightly . If u have the side stand still u can just pull the bike over on that and the back wheel will come up .

cool, thanks for the tip Lee!
 

Ryanthegreat1

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The stock muffler makes a great jack point.

I put the front end in a wheel chock and then jacked up the rear using a jack with a rubber pad on the muffler. That over weight boat anchor is good for something.

Then it was just remove the rear hugger and the shock will come right out.
 

RoninJames

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ok guys, i tried to install the ohlins R6 shock today and its just too tight under there with the stock can. i couldnt get it to fit.
the ohlins shock has a separate reservoir that is about a half inch or so away from the shock... unlike the oem R6 shock that is all one piece.

I have no doubt once i get an aftermarket exhaust that creates some room in that area it will fit no problem. just gotta wait until i get a decent exhaust.

ohlinsrearR6.JPGshock.JPG
 

mr-fabricator

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I have a chance of a ohlins rear for $500 aud , not a bad price but will be waiting to see how the stock r6 shock performs .. this "entry level " bike should come with a finantial warning !! Ha ha
 
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