Ohlins Shock Installation on 2004

[Goobr]

Got my new Ohlins shock in from SuperBike Italia the other day and I'm about to change that stock puppy out. I ran across thread here the other day that had a link to a step by step installation with pics and stupid me didn't bookmark it. Any of you guys have that link or know what I'm talkin' about? I can't seem to find it now.

I'm a pretty good wrench, been workin' on all my bikes all of my life but if there are some tips and tricks to be used, I'll certainly exploit them.

Okay, out to the shop with me but I'll be checkin' back in here often.

Thanks,

Ben

 

[SilveradoSlick]

Well, there's this for installing a Wilbers: fjrtech

 

[Goobr]

Well, there's this for installing a Wilbers: fjrtech

Came in for a beer break.

Yeah, I saw that one and it should be dern near the same. I do remember the one I saw had a few caveats vs the enclosed instructions and as I have come up on those, thank goodness I remembered. For instance, when you are taking the dog bones loose, don't do it at the bottom because you can't get the bolt out as the center stand is in the way,,,,, remove the top bolt. I'm at that stage right now and am taking pictures along the way if anyone is interested.

Okie dokie, next step is removing the old shock. I'm having to work around all the ABS proportioning valves too. All that stuff is tucked in on the right side behind the side cover.

Just a nice weekend piddling on my bikes. I swear, sometimes I think I like workin' on 'em more than ridin' 'em.

 

[RenoJohn]

This (clicky) might be of use ...and when you finish up, I may have a couple of questions for you

 

[Goobr]

This (clicky) might be of use ...and when you finish up, I may have a couple of questions for you

That's the one I was lookin' for. Thank-you! I'd be happy to answer any questions you have though mind you, I'm not a very smart man.

That botton shock mount nut was a ****** to break loose. About to install the Ohlins now but I can't for the life of me figure out why I can't load it from bottom like the OEM came out. I'm gonna try,,,, I'm sure I'll find out why here in a few.

I should be wearing my leather,,,, at least on my wrists. LOL

EDIT: Okay, so it didn't take long for me to figure out why the Ohlins won't go in from the bottom. Stupid, stupid, stupid.................

 

[Goobr]

So I take lots of breaks,,,,, hey, it's the weekend right?

I'm a skeptic so I tend to try to take short-cuts if they're safe ones. I'm sure I'm not telling you guys anything but there aren't any short-cuts to this mod so far as on Ohlins shock goes.

The guys that wrote this "how to" did a jam up job.

The hardest part is over now. I got the shock in place but not bolted up. Time to start putting everything back together.

I'm not trying to sound like I"m puffing my chest but I'm a moderator on a couple other motorcycle forums and I would definately "sticky" the above link if it's not already. Good stuff,, good pics too. Thumbs up to the authors.

 

[Goobr]

Okie dokie, pretty much finished 'cept for the side covers. I'll do that in the morning with my coffee.

Everything went pretty much as the above link described. I tried a few short cuts but it wasn't to be. I haven't even sat on the bike yet to feel the action of the shock but I'll find out in the morning as I'm plannin' on goin' for a little ride. Below are some pics I took along the way today. I'm not a good technical writer but I can answer some questions if you guys have any about this mod. It wasn't hard/difficult, just time consuming.

Definately have to get that puppu up and above what the centerstand will do.

Remove the top dog bone bolt. Not the bottom one as the directions imply. If you're using the stock centerstand, the bottom bolt will not clear.

I haven't removed the subframe bolts as of this pic but you will definately need to remove them in order to slip in the shock just above the rider peg and just below the passenger peg. Trusr me,,,,, it works.

It will go in there, trust me. In this pic, I had not routed anything, I was just so dern proud that the shock was where it was 'sposed to be. LOL

Here's a shot from the top with nothing hooked up, no bolts, nuttin'.

Top mount bolted on. Be very patient here. I was gettin' a little flustered here. The length of the spacer in the shock is sooooooo close to the ID of the shock mount that's it's got to be square before it slides into place. I had gone so far as to thinkin' about takin' a ******* file and opening up the top shock mount,,,,,,, that would have been the wrong move. It will fit, I promise.

And you know what to do with the rest.

LIke I said, it wasn't hard, just time consuming and made me think a little. I'm lookin' forward to a little "spirited" ride down on the phosphate mine roads tomrrow. :yahoo:

 

[RenoJohn]

Goobr,

nice write up. I'm tardy on doing just what you did (Ohlin into an 04). One reason I haven't started, I recall someone saying you needed to use the Ohlin supplied mounting bolt for the lower attachment point(?) ..this didn't make sense to me, and I don't have an Ohlins supplied bolt. Did you just use the OEM one??

Thanks ...renojohn

 

[Goobr]

Goobr,
nice write up. I'm tardy on doing just what you did (Ohlin into an 04). One reason I haven't started, I recall someone saying you needed to use the Ohlin supplied mounting bolt for the lower attachment point(?) ..this didn't make sense to me, and I don't have an Ohlins supplied bolt. Did you just use the OEM one??

Thanks ...renojohn

Hey Reno,,,

Yes I did use the supplied bolt. In the box I received was a bottom bolt and also an aluminum cross brace that runs from one side of the sub-frame across to the other side. You didn't receive that?

The only thing I can think different in our applications is that there is a different part number for ABS and non-ABS '04s. I have an ABS model and the part number on the box I received is "YA 342". Does that help any?

On another note, I finished up putting the plastic back on and rechecking all the mounting bolts when I got home from work yesterday afternoon. Rolled it out of the shop for a quick spin around the lakes here in Lakeland,,, about 5 miles and top speed of about 40mph. When I threw my right leg over and sat down it was like "Hahahha,,, cool!" A whole different motorcycle it is now. I am very happy with it. Mind you, I bought the shock from the guy whom is the only one I let touch the suspension on my R1 track bike. He is an Ohlins dealer and tech center,,, he already had my weight and settings in his database so he got pretty dern close in setting up the shock before he sent it to me. I haven't done anything with the front end yet but seeing as I don't much ride during the summer months here in Floriduh, I'll probably send him the FJR forks for a rebuild this summer.

 

[RenoJohn]

Hey Reno,,,Yes I did use the supplied bolt. In the box I received was a bottom bolt and also an aluminum cross brace that runs from one side of the sub-frame across to the other side. You didn't receive that?

Non ABS hereAny reason the original bolt would not work?

 

[Goobr]

Any reason the original bolt would not work?

I'm not sure. I just used the bolt that Ohlins sent in the box. I still have the bike up on the work bench and can check tomorrow.

I know I'm a geek but I'm settled in tonight with beef ribs on the grill and watching the shuttle landing. I'm such a "ho".

For real, I'll take some measurements tomorrow after work as I have all the stuff still laying out.

 

[RenoJohn]

I'm not sure. I just used the bolt that Ohlins sent in the box. I still have the bike up on the work bench and can check tomorrow.
I know I'm a geek but I'm settled in tonight with beef ribs on the grill and watching the shuttle landing. I'm such a "ho".

For real, I'll take some measurements tomorrow after work as I have all the stuff still laying out.

LOL, thanks much, I appreciate it. If it turns out I need the special bolt, I'm glad I held off.

 

[BentAero]

I'm not sure. I just used the bolt that Ohlins sent in the box. I still have the bike up on the work bench and can check tomorrow.
I know I'm a geek but I'm settled in tonight with beef ribs on the grill and watching the shuttle landing. I'm such a "ho".

For real, I'll take some measurements tomorrow after work as I have all the stuff still laying out.

LOL, thanks much, I appreciate it. If it turns out I need the special bolt, I'm glad I held off.

Guys, If you get in a jam you can't get out of, don't hesitate to call Ohlins USA (in beautiful Hendersonville, NC) My close friend Stacey works there in the MC support division. He, Matt, or Mike can help you w/ your tech questions, and if they don't know the answer, someone down the hall will. 828-692-4525

 

[RenoJohn]

Guys, If you get in a jam you can't get out of, don't hesitate to call Ohlins USA (in beautiful Hendersonville, NC) My close friend Stacey works there in the MC support division. He, Matt, or Mike can help you w/ your tech questions, and if they don't know the answer, someone down the hall will. 828-692-4525

Me figuring that since they include and ship this one particular bolt and nut with the shock -perhaps it is different. So I called and spoke with Matt. Well, he couldn't tell me what (if any) the difference is. but he did tell me:- they don't stock them so it will take weeks to get one.....

- but he did have spec's on it (10 X 1.25 X 40 ....and a matching locking nut)

Nothing too crazy about this and should be no problem getting a descent one locally. Don't know (yet) how this compares to the OEM

 

[Goobr]

The bolts are definately different. The OEM bolt has 2 shoulders on it as the holes in the bottom shock mount of the OEM shock are different sizes.

I hope this helps,,, for reference in the instruction manual that came with the shock:

Bolt: M12x55 Part# 00439-16

Nut: M12 Part# 01501-01

I just pulled the bottom bolt and took a couple of pics.

 

[RenoJohn]

The bolts are definately different. The OEM bolt has 2 shoulders on it as the holes in the bottom shock mount of the OEM shock are different sizes.
I hope this helps,,, for reference in the instruction manual that came with the shock:

Bolt: M12x55 Part# 00439-16

Nut: M12 Part# 01501-01

I just pulled the bottom bolt and took a couple of pics.

LOL, well I'll be damned !! The OEM is quirkey, and the Ohlins is pretty standard. They definately are different and now it makes sense while Ohlins ships one with the shock. I'll replace my lost one and dig in soon.

Thanks much for taking the time and showing!!! Owe you a beerz. ....renojohn

 

[Goobr]

Owe you a beerz. ....renojohn

Hahaha,,,,, will work for beer! Sweet beeeer.

My pleasure.

 

[RenoJohn]

Well, threw mine in today. Been putting it off long enough.

Goobr, ..thanks for the pics and comments and big thanks to Marc L and **** M for their great write up. While not rocket science, there are many little "gotchas" to getting the Ohlins with resevoir into place.

Having to screw with the subframe at least doubles the effort of a typical shock install.

It would have been frustrating without the lead of others. Thanks guys. renojohn

 

[Goobr]

Well, through mine in today. Been putting it off long enough.
Goobr, ..thanks for the pics and comments and big thanks to Marc L and **** M for their great write up. While not rocket science, there are many little "gotchas" to getting the Ohlins with resevoir into place.

Having to screw with the subframe at least doubles the effort of a typical shock install.

It would have been frustrating without the lead of others. Thanks guys. renojohn

Hey!!! Cool beans!!!

Yep, Marc and **** did a great job on the write up and I looked at their procedure several times.

Glad ya got it goin' man. The hard part is gettin' started but then it seems like all the work is psych' preventive medicine. :yes: