Author Topic: ZZR 1200 Rear Shock  (Read 14676 times)

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Offline Slybones

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Re: ZZR 1200 Rear Shock
« Reply #50 on: May 13, 2012, 06:43:09 am »
I have read the 30-35mm sag for both the front and the rear. For the front its never been a problem. For the rear and the stock shock I had 46mm sag average with 30psi, and best was 38mm sag with 50psi, just me on the bike. With the wife and I 50psi was still 53mm average over several measurements.

With the ZZR shock I had 42mm with the adjuster on 2 and 34mm with the adjuster on 5. That too was just me. With the wife and I, adjuster on 5 best we got was the same 53mm with the ZZR shock.

Still I like the ZZR shock much better for riding 2 up. Even though the sag measurements worked out the same, I still recall thinking it didnt sag as much based on how I looked over the windshield, down the road. Seems like its smoother 2 up and does not bottom as much as the stock shock and 50psi. Like maybe it as a bit more spring rate to it. -- I like that when we ride 2 up all I have to do is turn the knob versus getting out the pump and measuring air pressure.


-- Of course this is my weight, Givi trunk full of all that stuff I carry, etc. Maybe someone 100 lbs lighter, no Givi, etc might get to 35mm without maxing the preload, but for my fat butt, gear and trunk full of stuff. I could only get close with max preload, and 2 up was not even close.
« Last Edit: May 13, 2012, 06:46:26 am by Slybones »
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Offline Dave Scott

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Re: ZZR 1200 Rear Shock
« Reply #51 on: May 22, 2012, 05:46:33 pm »

Well it worked.  I drilled thru the head of the bolt 1/2 way down the shank with a 7/64 drill bit.  I then measured down from the out side and drill through bushing and though to the shank to the first hole I made. I did not drill through the shank. For those of you who don't know what the shank is , it's the un threaded portion of a bolt, under the head and above the threads.  ;D. After that I used a 17/64 bit (bigger than the first hole) and drilled into the head just deep enough to that I could thread the hole with a 5/16x 24 tap for the zerk fitting.  The fitting I used I got at Lowe's.
The hardest part of this was drilling into that flipping bushing,...HARD as HECK. but doable.  I would recommend a drill press for the whole operation.  The total time to do this was 10-15 mins.

This is the end product, the hole in the bushing is on the back side of the bushing.


Cheers
Ron


Ron, just getting ready to start this as my ZZR shock is due to arrive today.  In your description above, you said you didn't drill through the shank.  you mean you only drilled part way to meet the hole down the middle of the bolt, right?  Is there a reason you didn't drill through?  was it just to retain as much strength in the bolt as possible?  I was thinking that two holes out of the bolt and 4 equally spaced holes around the bushing would give better coverage.

Dave

Offline SAS Mayhem

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Re: ZZR 1200 Rear Shock
« Reply #52 on: May 23, 2012, 04:07:47 am »
That is correct my friend, it was something that I noticed when I worked on F-4 and F-15's and other military aircrafts. Is that there was only one intersecting hole. Never all the way thru and when lubed ,grease alway made it all the way around.
Also I want to add, take it easy when drilling and use oil to keep your drill bit cool.

PS- we do need to meet up one day.  ;)

Cheers
Ron
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Offline WillyP

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Re: ZZR 1200 Rear Shock
« Reply #53 on: May 23, 2012, 10:38:16 am »
Does the bushing rotate on the bolt, or in the shock and/ or rocker? If the bushing moves relative to the shock, then you need grease on the outside of the bushing.

Oh, nvm, I see you did drill the bushing, it just isn't shown in the pic.
« Last Edit: May 23, 2012, 10:42:44 am by WillyP »
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Offline Dave Scott

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Re: ZZR 1200 Rear Shock
« Reply #54 on: May 23, 2012, 02:05:49 pm »
The shock arrived yesterday in perfect, pristine, never-used condition.  Bolt, nut and bushing on order.  A little bit of mill work and she'll be ready to install.  Just need to find a spare zerk fitting.  May have one sitting around from old parts.  we'll see.

Offline Wess

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Re: ZZR 1200 Rear Shock
« Reply #55 on: May 28, 2012, 08:50:26 pm »
Ok Guys I have the choice of a new zzr shock or a used one of the 14 for $10 more. 

What do you guys recommend?
Respectfully Yours! 
Wess Heavner 
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Offline GF-in-CA

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Re: ZZR 1200 Rear Shock
« Reply #56 on: May 28, 2012, 09:21:10 pm »
I have the ZZR shock, but would go for the C14 shock if I didn't already have the ZZR shock.  The C14 shock has a little more adjustability plus there are stiffer springs available for it.  You will need a lowering rocker to bring the rear ride height back to stock, whereas it is not necessary for the ZZR shock.

HTH,
Gary F.

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Offline 2fast

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Re: ZZR 1200 Rear Shock
« Reply #57 on: July 08, 2012, 06:34:22 pm »
I'm getting ready to install my zizzer shock and was just looking at the parts to see what I need. Could someone that has ordered the bolt/bushing/nut combo please tell me exactly which parts I need off the fiche?http://www.bikebandit.com/houseofmotorcycles/2003-kawasaki-zzr1200-zx1200c/o/m149285#sch297853

I find the drawing a little confusing and don't want to order the wrong stuff!

Thanks!!
Brian in Minnesota

Offline Wess

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Re: ZZR 1200 Rear Shock
« Reply #58 on: July 08, 2012, 10:51:12 pm »
Here are the parts on the ron ayers site as I just got them to do my zx14 shock  which I mocked up on my 91 today. now it will take an hour or so to swap it with the zzr12 on my 05.

http://www.ronayers.com/Fiche/TypeID/26/Type/Motorcycle/MakeID/3/Make/Kawasaki/YearID/46/Year/2005/ModelID/3902/Model/ZZR1200/GroupID/120943/Group/Rear_Suspension

Bolt 92153
Nut 92015
Sleeve 42036-1077

You will love the zzr I and my GF did.  I just went with the 14 because alot of people were saying in was the next step up and I have no impulse control.
Respectfully Yours! 
Wess Heavner 
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Offline 2fast

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Re: ZZR 1200 Rear Shock
« Reply #59 on: July 09, 2012, 12:30:52 am »
Thanks Wess, I appreciate it. I am somewhat surprised that the same parts fit both the ZZR and the ZX14 shocks, but that sure makes it easy :great:
Brian in Minnesota

Offline Wess

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Re: ZZR 1200 Rear Shock
« Reply #60 on: July 09, 2012, 10:50:26 pm »
You have to enlarge the bolt holes and grind the sleeve down a little but other than that it is pretty much a bolt on.  I was amazed it was that easy myself but Matt L. told me what to do.  I can't wait to get it on the 05 and take her for a run.  The only problem is that it makes the bike taller and I already have GT's on it so the GF may need a boost to get on.
Respectfully Yours! 
Wess Heavner 
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Offline 2fast

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p*SSED at Ron Ayers
« Reply #61 on: July 18, 2012, 10:45:53 am »
My package of parts for mounting the ZZR shock arrived from RonAyers yesterday. Got everything EXCEPT the bolt!! Looking closely at the little rcpt inside, I see a BO by the bolt, obviously indicating it was back ordered. Hey, without the stinkin bolt, I don't need the bushing and nut. Had they been polite enough to let me know this is in advance, I would have cancelled the order and gone somewhere else that had it ALL. Plus, no note about the back order at all, unless you notice the little B/O on the rcpt.  :-[

I will let them know how I feel about this and shop elsewhere after this.

Rant off.
Brian in Minnesota

Offline Dave Scott

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Re: ZZR 1200 Rear Shock
« Reply #62 on: July 18, 2012, 02:19:29 pm »
Same thing happened to me 2Fast.  Good news is the bolt arrived about a week later.  Just be patient and it should appear.  I haven't had a chance to get the machine work done yet to prep for the zerk fitting and mounting.  Some day after I get my fork seal to stop leaking and my boat repairs all done, I'll get to it.  I should probalby just outsource it to Ron.   :)

Offline Daytona_Mike

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Re: ZZR 1200 Rear Shock
« Reply #63 on: July 18, 2012, 06:03:18 pm »
I too purchased a new ZZR shock . I would like to do the 'bushing' conversion at the same time I install this shock.
Is there anything different to consider or recommendations?
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