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** Revised version of instructions are
here (Mar 2005) By
Scotty 02/04/2004 (AndyW) - NB: 2003 onwards
gixxer shocks have the reservoir on the opposite side to pre 2003
shocks and all stock SV shocks. I've recently (01/2005) fitted
a GSXR shock myself and will post a modified installation guide
soon.
 Here is how I replaced the
Standard Rear Shock with a 02 GSX1000 Rear Shock. Whilst my method
is not strictly text book it requires a minimum amount of tools and
skill. If you know your way around a set of spanners and sockets you
should be able to complete the job in under an hour, 2 hours for
those of us less mechanically minded (myself included).
Tools/Equipment Needed
*Set of Spanners
*Set of Sockets and Wrench
*Torque Wrench
*4 Tie down Straps
*Bottle Jack or Car Jack
*Grease
1.Ok first step is to turn around the base of your GSX Shock so that
when it is mounted on the bike you will be able to get to the
Re-Bound Adjuster. If you leave it where it is, a part of the
Exhaust System on the left hand side will obstruct you from getting
to it. Simply loosen off the Pre Load Spring Collars a couple of
turns then put a screwdriver through the two holes in the bottom
bracket and turn the bracket 180 degrees. (You will need to set your
static sag and personal suspension settings once the shock is
mounted so don’t worry about putting the preload spring back to
where it was.) I have used the SV1000 spring for illustration
purposes.
Fig 1.
 2.Time to attack the bike. Whilst the bike is still on it side stand
loosen off the nuts/bolts on the top of the shock. Next loosen off
the bottom nut/bolt (2) on the shock. Loosen the bottom nut/bolt (3)
holding the dog bones onto the Rear Cushion Lever
Fig 2
 3.Ok this is the scary bit. Lifting the rear of the bike off the
ground. There are various methods used by members on the SV site,
(do a search to find them)(Edit=AndyW: I'll put some information
together on that as soon as I can...meantime if anyone wants to
submit suggestions please do) but I wanted to make mine a little safer
than just jacking up the rear of the bike then sticking a couple of
pieces of timber under it for support. Basically you do need some
form of support on either side of the bike and preferably higher
than shoulder height. (Edit=AndyW: an
Abba Stand would be
perfect for this job) Place the jack under the part of the Exhaust
that is pointed out in the above picture and jack up the rear so the
rear wheel is just off the ground (don’t worry, the weight of the
bike will not crush the exhaust). Once its off the ground its time
to secure the bike from toppling over. Like the saying goes “a
picture says a thousand words". I used the pillion peg bracket as the
support point. The “all blue” strap is the one that takes all the
weight, the “orange and blue” strap is there simply to stop it from
toppling over so does not have to be super tight. Once the straps
have been put in place and, tightened accordingly, SLOWLY lower the
jack making sure the wheel is still off the ground once it has
compressed totally.
Fig 3
Fig4
 (Please refer to Fig 2. for the next 2 Steps)
4.Once the wheel is off the ground loosen the Dog bone bolts (3) and
remove the bolt. Then remove the bolt securing the linkage to the
base of the shock (2). The shock should now only be secured by the
top bolt. Remove this bolt but be careful as there is nothing
stopping the shock from dropping to the ground after the bolt is
removed. You will find the shock will come out quite easily.
5.Installing the GSX Shock. Basically the reverse of what you have
just done but there are a few things to watch out for. Make sure the
shock is installed with the gas reservoir towards you (right hand
side of bike, it will fit quite close to the Rear Brake fluid
Reservoir.) Apply a little grease to all the mounting bolts. Install
Bolt and Nut (2) first, as the exhaust system gets in the way of it
being pushed into the hole once the top bolt (1) is put in place.
Next put in the top shock Bolt and Nut (1) then comes the fiddly
bit. Using the jack to Manoeuvre the bike, install the last Bolt and
Nut through the Dog Bones (The GSX Shock is slightly longer than the
SV Shock so will take a little more fiddling to put in place). As a
side note just tighten these nuts and bolts. You can torque them
once the bike has two wheels safely on the ground.
6.Once you have put all the bolts back in place, loosen off the tie
downs and slowly lower the bike back down to the ground.
7.Torque down the bolts to the required specs. The Fig 5. shows the
relevant torque settings.
Fig 5.
8.Go for a short ride just to make sure everything is smooth in its
action, then ……….
HAVE A BEER.
Cheers
Scotty
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