Shock Swap In The Books!
We got home by 2:30pm and headed for the garage. I pulled the old shock from the Ninja and got to work removing the eyelet bushing which to my surprise, came out in less than a minute. The real job was to get it to fit the new shock. Instructions say to open the eyelet on the SV650 shock another 20 thousandths. Easier said than done!
I started with a curved file inside the eyelet for what seemed an eternity. Set the bushing in place, nothing doing. Without a lathe or a bit that big, this was going to be a chore. I immediately went to plan "B". I sent Richie upstairs for the Dremel kit. I cut a tiny section the long way on the bushing which in theory would close it just enough to make it's diameter a perfect fit. Being that it is sandwiched in the eyelet and between the upper mount flanges, there would be nowhere for it to go. I had to be almost sure since there was no turning back once I broke that metal wheel out. Once the section was cut into the bushing, I used a 1" hose clamp to compress it closed and pressed it into the eyelet. It worked like a dream. The last 1/4" (width of the hose clamp), was pressed in the same way I removed it initially, back to back sockets with a 3/8 threaded grade 8 bolt through them. I cinched down on the nut and in went the bushing. Next I drilled out the bottom eyelets to 1/2" in order to fit the stock bolt. I grinded the lower ears a bit since they are a tiny bit narrower than stock and filed everything smooth. I lifted the new shock into place and Richie sent it home while I lifted the rear of the bike to it's new ride height. I used the rubber mallet to line up the holes. Richie inserted the bolts and we snug everything down. Once finished the difference was apparent. You can now use one finger the get the bike on the centerstand, and I think I'll be needing a longer kickstand. The bike doesn't tip over but at over 1-1/2" higher, it's real close to it's limit. I may pick up a sacraficial kickstand to cut and have welded into place to add an inch or so to the stock stand. Richie sat on the bike and is now on the balls of his feet. Also, the rear height is looking good now and there is no longer any sag in the rear. I have it set on 4 clicks preload, but it won't be until he rides it that I'll do some adjusting. Here are some shots that Richie took today.............
The two shocks side by side..........
Getting ready to remove the stock shock......
Shock removed. Didn't even have to remove the wheel......
Trying to enlarge the eyelet on the SV650 unit............
Here goes Plan "B"......................
Now to compress the bushing.............
Pressing in the bushing..................
Taking some material from the lower flanges.............
New Shock Installed !!!!!!.......................
If this mod is anything like they say it is on the 250 Ninja Forum, Richie will be having a better time on the mountain next time. Next and LAST mod, the front forks. I'm gonna use the site that Tony "the Bloodhound" sent me and go with the 70gm set of non-progressive springs with 15W oil. It's supposed to eliminate the dive and the front end more compliant for riders at about 160-170lbs. That will have to wait for another day. Thanks for looking!
Nice!
