03 636 Rearset Installation Problem needs help - ZX6R Forum
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post #1 of 12 Old 02-17-2017, 01:53 PM Thread Starter
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03 636 Rearset Installation Problem needs help

Hi, I am new to motorcycle and this forum. I recently broke my stock rearset so I got a new set on eBay.
It arrived yesterday. When I tried to install the shift lever side it was alright. But I have encountered some issue when doing the rear brake side and I need your help!

The stock rear brake pedal has an external return spring, but it looks like i can't use it on the new aftermarket rearset(it is what it said in the instuction)
how do I install this rear brake without the return spring? where should i hook the rear brake light switch spring to?

Btw it was Danmoto rearset.
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post #2 of 12 Old 02-17-2017, 03:25 PM
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The ebay ad has some specific instructions regarding this:

Adjustable Billet Rearsets Black Kawasaki ZX 6 R Ninja RR 2003-2004 03-04 FR59 | eBay

But hey, let me know how they work out. I'm 6'2" on an '03 myself and adjustable rearsets would be a good idea.
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post #3 of 12 Old 02-17-2017, 04:17 PM
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Originally Posted by NinjaTemp View Post
The ebay ad has some specific instructions regarding this:

Adjustable Billet Rearsets Black Kawasaki ZX 6 R Ninja RR 2003-2004 03-04 FR59 | eBay

But hey, let me know how they work out. I'm 6'2" on an '03 myself and adjustable rearsets would be a good idea.


I do not know about your application, but most rear brake have a spring associated with the master cylinder; perhaps this might help:

SATO RACING | BRAKE RETURN SPRING

I think Sato are a reputable rearset manufacturer, and if they are selling a secondary spring for even more sure pedal return, I might go, "hmmm?"

I suspect their (Danmoto) math might be off. It's probably a function of price point. The brake cylinder of this bike has an internal return spring, which is more than sufficient.The fact that these rearsets do not have an external return spring is no lack of safety or function.99% of all aftermarket rearsets come without such a spring, because it's simply not needed from a technical point of view.


My very lovely Rizoma rearsets came with a whole new set of anodized retaining collars and a very noticeably stouter spring than even O.E.M.

I would think with a little imagination and a little time you could remedy a fix.
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Last edited by ZedExMuse; 02-17-2017 at 04:21 PM.
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post #4 of 12 Old 02-17-2017, 05:23 PM Thread Starter
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Quote:
Originally Posted by NinjaTemp View Post
The ebay ad has some specific instructions regarding this:

Adjustable Billet Rearsets Black Kawasaki ZX 6 R Ninja RR 2003-2004 03-04 FR59 | eBay

But hey, let me know how they work out. I'm 6'2" on an '03 myself and adjustable rearsets would be a good idea.
yeah, i will post as it's done. I am 6' so the stock rearsets are not too bad, only sometimes my thigh joint hurts.

I've read the instruction they provided, but not sure how it could be done. It is raining in Cali so I will start figuring it out next week
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post #5 of 12 Old 02-17-2017, 05:28 PM Thread Starter
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Quote:
Originally Posted by ZedExMuse View Post
I do not know about your application, but most rear brake have a spring associated with the master cylinder; perhaps this might help:

SATO RACING | BRAKE RETURN SPRING

I think Sato are a reputable rearset manufacturer, and if they are selling a secondary spring for even more sure pedal return, I might go, "hmmm?"

I suspect their (Danmoto) math might be off. It's probably a function of price point. The brake cylinder of this bike has an internal return spring, which is more than sufficient.The fact that these rearsets do not have an external return spring is no lack of safety or function.99% of all aftermarket rearsets come without such a spring, because it's simply not needed from a technical point of view.


My very lovely Rizoma rearsets came with a whole new set of anodized retaining collars and a very noticeably stouter spring than even O.E.M.

I would think with a little imagination and a little time you could remedy a fix.
That looks nice! Yeah I went for cheaper chinese rearsets but after reading all the reviews i think i can make it work.
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post #6 of 12 Old 02-18-2017, 12:40 AM
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It looks to me like the spring would connect to the rear brake lever here:

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post #7 of 12 Old 02-18-2017, 12:44 PM
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its only a return spring you can run the rear brake without as i have done for the last four years without a problem

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post #8 of 12 Old 02-18-2017, 12:46 PM
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for the brake light switch install a banjo pressure switch that will get the brake light up and running for you
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post #9 of 12 Old 02-18-2017, 03:37 PM
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post #10 of 12 Old 02-22-2017, 12:47 PM
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Quote:
Originally Posted by scoot33 View Post
for the brake light switch install a banjo pressure switch that will get the brake light up and running for you
I do not use brake light switch at the brake pedal (partly because I tend to do a bit of trail braking). But, I do use a brake light sensor at the brake lever.
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post #11 of 12 Old 02-22-2017, 03:09 PM
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Quote:
Originally Posted by ZedExMuse View Post
I do not use brake light switch at the brake pedal (partly because I tend to do a bit of trail braking). But, I do use a brake light sensor at the brake lever.
Weird, you have your throttle cables coming out under the clipon instead of above/in front of the clipon. What is the reasoning behind that?

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post #12 of 12 Old 02-28-2017, 08:28 PM
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Weird, you have your throttle cables coming out under the clipon instead of above/in front of the clipon. What is the reasoning behind that?

Sharp eye; I learnt this from track day riding my CBR 1000RR. Too often as one pushes the right clip-on full right (forward) the throttle cables contact the double bubble windscreen on the right side. If left un-checked the windscreen gets marred, and the black plastic sheath surrounding the cables starts to wear thin. So, I orientate them away from the negative situation (below).

I found the same situation with my ZX-6R, thus, resorted to the same Fix. The lines/cables are also "tucked up," and less likely to be at risk in the event of an unplanned get-off. I think it looks a bit more tidy, too.
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