636 Shock Installation Help

[fpugsley]

So i got my 636 shock in and attempted to install it today... There are a few problems, and I could use some input.

1. The ignition coil is in the way of the remote reservoir
2. The bushing on the lower pivot is too wide and the lower pivot is too wide to accept the 636 shock yoke.

What am I doing wrong?  Or has anyone solved these problems?

[mashean]

hello.

1) everybody just turns the ignition coil around and re-routes the wire (so the plug faces the rear tire)

2). some grind the ears on the shock to accept the yoke.. or you could grind the yoke (up to you).  There are some model 636 shocks that don't need any modification (2002 is one of them).  I have an 07 shock on mine but it came with the linkage so I replaced everything and it works great.

[Daveejayuk]

http://zee750s.com/zeeforum/viewtopic.php?t=831

the regulator/rectifier is the leccy bit that gets in the way of the gas canister - I think my unit was off a 2003 zx636rr, and slipped straight in without an issue with the mounts ata ll - I know some of the Z1000 owners on riderforums got into milling and grinding to get theirs to fit....

[fpugsley]

Thanks guys... When I was falling asleep I couldnt stop thinking about it and I decided I was going to put the shock on the grinding wheel or take it to a machine shop.  Another excuse to spend some time in the garage!

[fpugsley]

To make the 05 636 shock fit without grinding anything I needed these parts:
42036-1258 - Sleeve
92049-1225 - Oil Seal

they replace the components where the shock mounts at the bottom pivot (which is the same part as the 05 636).  The z750s parts are too wide to fit in the 636.  with these new parts, it fits perfectly.  And it rides a ton better.  Always feels hooked up in the rear.  It might ride a little higher back there too.

and here it is

[tom34]

Hi great mod!

Can i ask how it feels different than the stock shock?

And is it a big difference or minor?

cheers

[fpugsley]

So far the difference feels huge and I have only had time to drive it around a little.  It is firmer than the stock shock, and maybe that is because i upped the preload.  I think the valving of the shock itself is responsible for a lot of the good feel.  The rear always seems to stay planted on the ground over little bumps.  I havent taken any good highway turns on it yet, maybe this weekend!

I still dont have the settings just right and i dont have access to the manual to tell me what it should be, so its trial and error

Oh, and my total cost out of pocket was:
Shock $35 on ebay (incl shipping)
Misc parts $20 from Ron Ayers

Install time: <1 hour maybe. But that was on the second attempt so we knew what to expect.

[fpugsley]

Got some settings info from another forum

Rebound (at the bottom) 9 clicks out (anticlockwise) from fully clockwise
Range is 0 hard to 15 soft which is 2 turns.

Compression (top) 3/4 turns out from fully clockwise. Max soft 2 turns out.

Spring preload 182.7mm standard
Useable range 177.7 to 187.7mm

For 68kg 150lb rider

[yorky999]

Great mo and good price for the rear shock.
Ps, I would just like to say get yourself a rear hugger to protect all the underside of bike and that nice rear shock.

[Neo Rabid]

03-04 zx6rr shock is supposed to be a straight drop in. LIES!!! doesnt really require much though.

Tools needed:
Ratchet, 3"-6" extension, 10MM socket, 10MM wrench, 12MM socket, Straight screwdriver or small prybar, Phillips screwdriver, Hammer, Small Floor Jack.

Step 1: turn the igniter/rectifier (whatever it is).
take it off, unplug it reverse it. 10MM socket needed

Step 2: Reroute the plug for rectifier.
Take out battery, remove side covers (both sides, makes it easier). pull the plug up through the bottom. towards the the airbox. pull the junction box up (to get the wires out of the way) use a small prybar or skrewdriver to lift the battery tray so that you can slide the plug through directly under the box. plug in the rectifier and put everything back.


Step 3: Shock removal
Remove the nuts on the shock (12MM - top requires the extension). Use the straight skrewdriver to knock out the bolts, **before you fully remove the bolts make sure to use the small floor jack to lift up on the engine (I used the oil drain plug to jack from) **. take shock out, leave the jack lifted as the bike will just drop down and you wont be able to accomplish anything.

Step 4: Sleeve Modding
Remove the lower sleeve and make sure it fits in the ears of the shock, if not make modifications to the sleeve so that it does. Takes probably 5 minutes to make the modifications with proper tools, I used a chopsaw and ground it off by placing it on the side. You can also buy a new sleeve from a zx6r but it just doesnt make sense when you have the tools to do the job yourself. Place it back from where you got it make sure that it is smooth and no sharp edges.

Step 5: Shock Install
Drop the shock in from the top, resivoir faces toward rearof bike place the bolt in the top and adjust the bottom ears to fit the bottom bolt in (may require you to raise or lower the engine with the lift to fit). put nuts back on bolts and sit on the bike, make sure your shock is good before you pursue torqueing everything down.


Step 6: Yell and kick
As you have just completed your 03-04 zx6rr 636 shock install!

Feels much better than the OEM shock, feels like its planted at all times on the rear but the front feels off now (soft) oh well. Wish I would have taken pictures so that I could make a pictorial instructional walkthrough, wasnt thinking.
stole the pics from fpugsley. His is an 05 shock not an 03-04 but it is essentially the same, the resivoir is silver and the spring is black on the 03-04.

[wangZ750]

Finally :?:

Thanks in advance for your assistance and RIDE SAFE!!

wang

[tenaciousz]

Just installed a 04 636 shock and it has transformed the bike. Much smoother over bumps and the shock feels like it follows the road surface much better. This is because it has rebound damping adjustment where the stock had NONE. The stock shock had a brutal bounce on bumps, jolting. The 636 shock is a godsend and a great mod for $50. Highly recommended.