01-06-2010, 07:37 PM
05-06 Swingarm installation on 03-04 636 ZX6R/RR :
Here are the instuctions for installing an 05-06 swingarm on an 03-04 636 ZX6R/RR. The 05-06 swingarm is much stronger/ stiffer and better looking and really bring the bike UP TO DATE!! It's what Kawasaki forgot to do! The 05 swingarm is only 5mm longer which is negligible to the wheelbase and handling/ steering response.
I will be referring to 03-04 year as 03 and 05-06 as 05 which are same.
Part needed:
Take measurements of the length from a fixed point on the bikes subframe to the swingarm axle position. (The 05 swingarm is only 5mm longer so it's not that critical. I used the 3rd mark for the adjuster.)
Remove the upper & lower shock mount pivot bolts and the upper link bolts and remove the shock. Using the Pivot nut wrench "Special Tool", remove the swingarm shaft pivot nut. I used a 1 1/16 socket that I cut with a cutting wheel and hi-speed grinder.
Remove the Pivot shaft nut on LH side and the pivot shaft. Remove the stock swingarm from the bike.
On the 03 & 05 swingarms, remove the RH seals and swap the 03 seal to the 05 swingarm. Install the 03 collar on the 05 swingarm. On the RH side, remove the chain guide and cut a rectangle slot in the guide and trim the retainer as shown to clear the TAB on the inside of the frame/ pivot area. Also install the large flat 05 washer as shown. If the 05 washer is missing, use the 03 cupped washer by grinding the lip off.
At this point you may want to grind off 2 chain link rivets and seperate the chain but do not remove it from the bike.
Position the 05 swingarm and install the pivot shaft thru and tighten the pivot shaft to 18 ft lbs. Loosen the shaft and retighten to 14 ft lbs. Tighten the pivot nut with "Special tool" to 72 ft lbs and tighten the LH pivot nut to 81 ft lbs. Move the swingarm up and down to check that it moves freely.
Re-attach the shock and linkages and check you measurement again and compare. (It may be necessay to shim the lower links 1mm-2mm to match the offset and prevent misalignment. Check to make sure.) Ride height should be the same if you used the 03 shock. Replace the rear caliper bracket & hose with the 05 units and bleed the brakes. I put the caliper at highest point to allow all the air bubbles to escape to the top bleed point/ screw and bletd the brakes. Use a wrench or some type of spacer to prevent the pads from closing. Install the rear sprocket from the 03 hub to the 05 hub and install the wheel on the bike. Feed the chain thru the bracing and install using the masterlink. Adjust your chain and tighten the axle nut & secure with cotter/ hitch pin.
DOUBLE CHECK YOUR WORK TO MAKE SURE ALL THE NUTS, BOLTS AND LINKAGES ARE TIGHT & SECURE!!!
Done ,Take the bike for a testride: make whatever suspension adjustments necessary and go riding.
Here are the instuctions for installing an 05-06 swingarm on an 03-04 636 ZX6R/RR. The 05-06 swingarm is much stronger/ stiffer and better looking and really bring the bike UP TO DATE!! It's what Kawasaki forgot to do! The 05 swingarm is only 5mm longer which is negligible to the wheelbase and handling/ steering response.
I will be referring to 03-04 year as 03 and 05-06 as 05 which are same.
Part needed:
- 05 Swingarm (05 shock and pivot only if upgrading to 05 shock)
- 05 axle and wheel spacers
- 05 Wheel and sprocket hub
- 05 rear disc caliper bracket and brake hose with clamp
- Kawasaki part# 92058-0007 EK 520 X-ring chain masterlink. (other brands fit too loose; the pins are smaller)
- Swingarm pivot Nut wrench P.N. 57001-1541 (Make one using a 1 1/16" Socket. Dealer wants $60)
- Torque wrench 0-100 Ft lbs (free loan-a-tool at auto parts stores; e.g. Autozone)
- Swingarm stand
- 2 Small Jackstands.
First, put bike on swingarm stand and remove lower fairings. Position the jackstands under the frame at the flat spot on both LH & RH sides and adjust the jackstands up to the bottom of the frame. Use a nylon ziptie to squeeze the front brake lever and tie around the throttle & brake. Carefully remove the swingarm stand and make sure the bike is stable & secure. Remove the rear wheel assembly and put away.
Take measurements of the length from a fixed point on the bikes subframe to the swingarm axle position. (The 05 swingarm is only 5mm longer so it's not that critical. I used the 3rd mark for the adjuster.)
Remove the upper & lower shock mount pivot bolts and the upper link bolts and remove the shock. Using the Pivot nut wrench "Special Tool", remove the swingarm shaft pivot nut. I used a 1 1/16 socket that I cut with a cutting wheel and hi-speed grinder.
Remove the Pivot shaft nut on LH side and the pivot shaft. Remove the stock swingarm from the bike.
On the 03 & 05 swingarms, remove the RH seals and swap the 03 seal to the 05 swingarm. Install the 03 collar on the 05 swingarm. On the RH side, remove the chain guide and cut a rectangle slot in the guide and trim the retainer as shown to clear the TAB on the inside of the frame/ pivot area. Also install the large flat 05 washer as shown. If the 05 washer is missing, use the 03 cupped washer by grinding the lip off.
At this point you may want to grind off 2 chain link rivets and seperate the chain but do not remove it from the bike.
Position the 05 swingarm and install the pivot shaft thru and tighten the pivot shaft to 18 ft lbs. Loosen the shaft and retighten to 14 ft lbs. Tighten the pivot nut with "Special tool" to 72 ft lbs and tighten the LH pivot nut to 81 ft lbs. Move the swingarm up and down to check that it moves freely.
Re-attach the shock and linkages and check you measurement again and compare. (It may be necessay to shim the lower links 1mm-2mm to match the offset and prevent misalignment. Check to make sure.) Ride height should be the same if you used the 03 shock. Replace the rear caliper bracket & hose with the 05 units and bleed the brakes. I put the caliper at highest point to allow all the air bubbles to escape to the top bleed point/ screw and bletd the brakes. Use a wrench or some type of spacer to prevent the pads from closing. Install the rear sprocket from the 03 hub to the 05 hub and install the wheel on the bike. Feed the chain thru the bracing and install using the masterlink. Adjust your chain and tighten the axle nut & secure with cotter/ hitch pin.
DOUBLE CHECK YOUR WORK TO MAKE SURE ALL THE NUTS, BOLTS AND LINKAGES ARE TIGHT & SECURE!!!
Done ,Take the bike for a testride: make whatever suspension adjustments necessary and go riding.