03/04 B1H rear shock swap - a bit of info - ZX6R Forum
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post #1 of 26 Old 04-16-2013, 03:53 AM Thread Starter
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03/04 B1H rear shock swap - a bit of info

I have just replaced the standard shock on my B1H with a virtually new one from a 2012 bike and thought I'd share some useful information.

Beforehand, I did a lot of searching to see exactly what additional parts were needed and what difference it would make to the geometry of the bike, but couldn't seem to find any definitive answers.

I bought a shock, plus entire linkage and measured everything up. Both shocks are 338mm long between the centre of the top and bottom mounting holes. The linkages are virtually identical within a mm or so, therefore, there should be virtually no change in the geometry of the bike. The main difference is that the mounting gap at the bottom of the 03/04 shock is 32mm and only 30mm on the 09/12 one.

After removing the old shock, I went to remove the linkage arm, but the bolt holding the linkage to the frame wouldn't come out without removing the exhaust downpipes. So after looking at both linkages and measuring them, I discovered that I could leave the existing linkage in place and just swap the sleeve and 2 oil seals (circled below).

The main uni-trak arm part of the linkage is exactly the same width where the shock bolts on, it's only the sleeve and oil seals which makes it 2mm wider on the B1H. These only cost about £15 to get the 09/12 parts. The added benefit of keeping the B1H linkage arm is that it has grease nipples, so you don't have to take it apart to grease it up.

I'm guessing that there is similarly very little difference with the 05/06 and 07/08 shocks/linkages as well as the above.



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post #2 of 26 Old 04-16-2013, 05:27 AM
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03/04 B1H rear shock swap - a bit of info

I'm curious. Why does every 03/04 636 owner always refer to their bike as a B1H? Yeah I know that's the model number, but why include it? I don't refer to my 06 ZZR fighter as a J6F.

Anyways the shock swap is a very common mod. I'm surprised to hear that the shocks from the 03/04 636 and the 09-12 are the same length. I measured an 05/06 636 shock against my 09 and they were not the same. I believe the 09 was 5 mm or so longer. My stock J shock was still a little longer than the 09 shock, so I just added a spacer (large washers) to keep the same geometry. Pretty simple solution.

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post #3 of 26 Old 04-16-2013, 06:01 AM
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You can actually just loosen the header a bit to get that last bolt out. It's not to bad getting to all the header bolts once you swing the radiator up.
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post #4 of 26 Old 04-16-2013, 06:13 AM Thread Starter
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You can actually just loosen the header a bit to get that last bolt out. It's not to bad getting to all the header bolts once you swing the radiator up.
I was just about to do that, but realised that changing the sleeve and oil seals was simpler as I already had them in the newer linkage.
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post #5 of 26 Old 08-08-2013, 10:49 AM
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Good info here, I knew the 05-08 shocks were a bolt on to the 03-04 but I wasn't sure about the 09-12 shock.


Quote:
Originally Posted by LarryJ View Post
I'm curious. Why does every 03/04 636 owner always refer to their bike as a B1H? Yeah I know that's the model number, but why include it? I don't refer to my 06 ZZR fighter as a J6F.
Possible because there were three different models made in the 03-04 range. Technically an 04 would be a B2H but it's still the same model as the 03 B1H. The other two models were the 03 ZX6RR K1 and the 04 ZX6RR M1. Or maybe it's b/c B1H is shorter than typing out 03-04 636 . I usually just call them B's.
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post #6 of 26 Old 06-22-2014, 04:29 PM
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Brands6R, thanks again for putting this info together. I just swapped a '12 shock into my 03 ZX6RR exactly as you did and it looks like there no notable change in ride height or anything as you said. Can't wait to try it out!

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post #7 of 26 Old 11-07-2014, 05:58 PM
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suspension settings

hi, I made the same swap as you for the 2012 rear shock. im wondering how did you go about your suspension settings after changing the rear shock??
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post #8 of 26 Old 11-07-2014, 08:03 PM
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Have look at the 2012 manual and start with stock. I found I needed more preload and a couple of extra clicks comp and rebound. It I ha e it set up for mainly track use
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post #9 of 26 Old 11-07-2014, 11:18 PM Thread Starter
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Off the top of my head, I think I've got pretty much the stock settings, but had to add 5 clicks of rebound damping, because the rear was pogo-ing out of corners at the standard 15 out. Works good on the track for me.

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post #10 of 26 Old 03-14-2016, 08:27 AM
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Hi great info thanks for sharing. I'm after putting an ohlins 2003 shock into my 2010 raf model would this just be a straight swap? Thanks
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post #11 of 26 Old 01-22-2017, 05:04 PM
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Hello everyone ! I need some advice

I am planning to change my 2003 ZX-6R shock with used 2012 ZX-6R shock.

I see that there are no problems to fit it except that 2003 bottom shock sleeve length is 32 mm and 2009-2012 is 30 mm.

But I was thinking why not to buy 2016 shock ?
I see that mounting sleeve on 2016 is the same 30 mm.

The only problem I see in shock stroke:

year 2003 - length 340 mm +12/-0 mm, stroke 72.5 mm;
year 2012 - length 341 mm, +2/-4 mm, stroke 64 mm
year 2016 - length 341 mm +2/-4 mm, stroke 64 mm

all info from https://www.ohlins.com

So I don't see any difference from 2009-2012 and 2013-2016 shocks

Should I use 2012 shock or maybe I could mount 2016 as it will have less wearing....
And what about stroke difference ? I'm afraid to bottom out the shock as it could result to crash :/
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post #12 of 26 Old 01-24-2017, 05:49 PM
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Just ordered a 2012 rear shock for my 03 B1H. I need to order the sleeve and oil seals now. Still a few months till the snow goes, can't wait to try this out.
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post #13 of 26 Old 01-25-2017, 12:46 AM
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Quote:
Originally Posted by novak View Post
Just ordered a 2012 rear shock for my 03 B1H. I need to order the sleeve and oil seals now. Still a few months till the snow goes, can't wait to try this out.
I'm also waiting for the snow melt

I am thinking to make a risk and order 2013-2016 shock as it will have less wear...
I think it should be the same shock with the same adjustments: spring rate, compression damping, rebound damping, high speed compression damping

on OHLINS site I see the only difference in fitted spring:
KA 361 - 2009-2012 - 21040-31 (Y)
KA 362 - 2013-2016 - 21040-36 (Y)

so on 2013-2016 zx6r the spring should harder. I don't know is it the same situation on OEM shocks....

and yes the sleeve has to be 2 mm shorter.... so I will need to buy it to...
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post #14 of 26 Old 01-25-2017, 12:57 AM
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I checked manuals and here is the difference:

2013-2016 shock don't have high speed compression damping adjustment and the spring length is 205 mm

2009-2012 spring length is 179 mm

2003 spring length is 180 mm

so 2009-2012 shock is more close to 2003
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post #15 of 26 Old 01-25-2017, 05:38 AM
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Quote:
Originally Posted by klaustukas View Post
I checked manuals and here is the difference:

2013-2016 shock don't have high speed compression damping adjustment and the spring length is 205 mm

2009-2012 spring length is 179 mm

2003 spring length is 180 mm

so 2009-2012 shock is more close to 2003

You're probably best going with an 09-12 shock, especially since others have done it and seem to have had luck with the set up. Lots of them on eBay, that's where I found the one I ordered.
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