Trying/failing to fit rear shock absorber to z750

[Zeus]

I've got a z750 2005 and I'm trying to install a rear shock absober from a "Kawasaki Zx-6r Zx636 2005 - 2006 C1h C6f" This is a common mod for my bike so it should fit no problem. The issue is the shock is rubbing aganist the dogbone mounting. I thought maybe I was being an idiot, but I was able to get the old rear shock to slide right over the dogbone mounting and align the two holes. Any thoughts?


Thank you.

https://i.ibb.co/zFvcZYg/IMG-20221221.jpg

[stinkwheel]

Exactly which bit of the shock is rubbing against which bit of the linkage?

On your picture it looks like the fork end of the shock isn't going over the sleeve in the uni-trak casting but looking at parts lists, the spacer sleeves are exactly the same part on both bikes.

If that's what's fouling, it's probably just some slight burring on the alloy inside the shock fork-end. Easiest thing to do in that case would be to take the shock back off, push the sleeve out of teh unitrak and check for fit with it on the bench. You might just need to lightly sand the inside face of the fork end. Or the fork-end might be very slightly rotated in reference to the unitrak. Or the previous owner of the shock might have ramsheed it on so tight they pinched in the fork-end slightly.

Or is it fouling elsewhere?
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Zeus]

Thanks for the reply. I reuploaded the image with an arrow showing where the contact is.

I'll give the inside of the shock a light sand tomorrow.

If the shock had been ramsheed in tight wouldn't it show some signs of distress? It looks be in good shape at least looking with a naked eye.

Also whats burring? Not heard that word before.

Thank you.

https://i.ibb.co/myWZfdx/shock.jpg

[stinkwheel]

Ok. As far as I can see based on the models you've given and the online parts lists, that should fit. The steel sleeve will push sideways out of the casting and ought to be a good fit in that fork end. It'll be easier to see why it isn't fitting with both parts on the bench instead of with you lying under the bike.

A burr is a rough edge. So you could say it's burred if the smoothly machined inside faces of the fork end or the outside faces of the sleeve have been slightly damaged/scratched/folded over/roughened in fitting or removal.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Zen Dog]

If it doesn't have any obvious small obstruction on the inside of the "shock fork", the interior width of the fork is consistent when measured along it's length (i.e. it hasn't been squidged by being banged up too tight), and the sleeve that's meant to fit in between the fork is simply too large... you may have to consider the possibility that your new shock isn't what you think it is.
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Current - '94 VFR750FR (Dead), '00 VFR800FI, '11 600 Hornet - Previous - '11 CBF125, '10 Street Triple R, '92 MZ ETZ301, '05 TTR250, NSR125R, KMX125, "Honda" Win
My bike trip around S.E. Asia 2010/2011

[Easy-X]

Have you still got the old shock? Be curious to see what they look like side by side.
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Zeus]

I gave everything a light sand and put some grease on but no luck. Where the shock is rubbing, it looks maybe slightly different compared to the old one. Don't think you can really tell from the image below. I'm sure it's the right part as the serial number on the part is correct.

Thanks for the feedback guys but i'm going return it.

https://i.ibb.co/K6YH5VC/IMG-20221221-142541266.jpg

[Nobby the Bastard]

Is it just me or is the bottom one a different gap to the top one?
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[WD Forte]

What happened to measuring things?
Even a Poundshop plastic caliper run over the various parts would tell you what the problem is
If the new shocks internal dimension is say half a millimeter smaller than the old one I'd just dress it with a file, grease the fuck out of it all and carry on regardless.

Are you using the old bolt?
is it fit for purpose with no wear/shouldering?
does it fit in the new shock?
or does a new bolt fit it all ok apart from the internal error?
____________________
bikers smell of wee

[Zeus]

I double checked it with a tape and they are different. The old shock is 1.4 inches across and the new is 1.3 inches.

old
https://i.ibb.co/WFnS0n3/old.jpg

new
https://i.ibb.co/Hq9ynhD/new.jpg

[Nobby the Bastard]

Why are you using decimal with imperial measures? They famously don't get on and is the reason why only yanks use them.

That's clearly your issue though. They are early different sizes.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[jeffyjeff]

Not trying to come across as a smartass here, but you would probably be better off using the mm side of your tape measure, if indeed you insist on using that tool to measure the shock. The tape readings you posted are 1 3/16 vs 1 1/4. Surely Kawasaki specs the inner dimension of the lower shock mount in millimeters, not inches.
____________________
History shows again and again how nature points out the folly of men - BOC

[stinkwheel]

Yeah, as pointed out, the graduations on the imperial side of that tape measure are in 1/16" graduations.

In any case, as far as I can see from parts fisches, the unitrak sleeve that fits in that fork-end on both bikes ought to be 10.1mm ID x 18mm OD x 32mm long. The one on the 636 definately so.
https://www.cmsnl.com/kawasaki-zx636c1-ninja-zx6r-2005-usa-california-canada_model15710/sleeve-101x18x32_420361344/

Even given the inaccuracy of a measuring tape for this, it looks to be pretty much a bit under 1 3/16" which is a hair over 30mm so that fork-end is a fair bit too narrow. You can't fit a 32mm pin in a 30mm gap.

If it was me and I was happy with the shock itself, like WDforte, I'd just file it down a bit on either side. However, I'd worry your filing skills aren't going to be up to the task so I would advise against modifying a load-critical part of your bike at your current level of engineering experience. (Maybe I'm wrong, if you know the difference between a second and third cut file and understand what a stress-riser is, crack on).

Like Zen Dog, you have to question if that is ACTUALLY the shock it says it is because a ZX636C1 shock should have a minimum 32mmm (just over 1 1/4") gap. If it is the right one, what happened to it to make that gap nearly 2mm narrower than it ought to be?

Yes, send it back.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[WD Forte]

Tapes are for carpentry or dress making not engineering you philistine!!
and as mentioned, you should work in mm not inches on a jap bike

buy yourself some calipers even cheap ones like this will prove to be
far better then a feckin tape measure

https://www.ebay.co.uk/itm/363210994641?
____________________
bikers smell of wee

[stinkwheel]

[Nobby the Bastard]

And the award for the pun of the year goes to.....
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[Zeus]

Thanks guys. Shock returned.

[Easy-X]