2004 zx10r Project, part 6 Rear end action! Rear shock upgrade and new chain / sprockets

[@ruaraidhmcdonald-walker9524]

Probably one of the few jobs I’ve never done on a bike! Great videos as ever but the detail rebuild of the seal head including picking seals and drifting in/out of the bush would’ve been key. Please include these steps in your coverage, we want to see *more*!!

[@maciejb.476]

Great bike. I have it :)) Nice to watch I learnt a little bit

[@TrooperTed]

When you mentioned the front sprocket nut, I had a PTSD-esq flashback to 10+ years ago, doing chain and sprockets on my 04 ZX-10 on my driveway. First time doing a C&S kit and it was all going swimmingly until I got to that front nut. I ended up swearing so much, neighbors came out to check & make sure I wasn't having a mental breakdown 😄

[@obsession_engineering]

Oh I fully understand your pain. They must employ the winner of worlds strongest man to tighten them up!

[@thebones]

Great video Dave, the explanation of the maintenance of the shock was excellent.

[@motorcycle_workshop]

WooHoo! I got a mention in a Obsession video, thanks Dave 👍

[@obsession_engineering]

Thank you Paul, great to have such useful people close by!

[@paulaus]

A couple of strokes with a hand file are enough to get the heads of the chain rivets off without sending sparks from a grinder everywhere. Enjoying this resto project 👍

[@troywee4774]

thanks for the splendid upload. cheers.

[@MrGeorgeisonit]

Let's get it percolatin while you're waitin 🎶

[@ianhoyle8459]

Nice work

[@motorcycleman58]

Very intresting Dave, keep up the good work

[@stuwhite1969]

nice

[@tonyhansom3160]

Happy, prosperous and healthy New Year to you Dave, keep the videos coming please as an ex- motor cyclist I find your videos very entertaining . I like the way you clean everything down and lay out in the parts in order of strip down and then clean them as you build the units back up again. Hope to see you at Olivers Mount. Take care and ride safe.

[@obsession_engineering]

I do try to be methodical and clean and I'm glad it looks like it, most of the time!

[@stevesanelli90]

Race pattern shifting makes so much sense Dave because you can easily keep your knees gripping the tank when downshifting. Again, first class explanation of the rear shock. When will you be test riding your bike to feel the difference?🤔

[@obsession_engineering]

I may have the test ride already filmed... just not got as far as the edit yet!

[@3699-j9u]

Can you tell me were i can get one of these bladders for the rear shock one with the valve in it Don't know what size i need Love your vids bro

[@jstn_9421]

Great Video... I want to make the same revision on my shock (ZX-10R 05). I am curious if you can say me how much shock oil comes in the shock. Is there a specific amount or just as much until the shock is completly full?. Is it possible to refill the gas reservoir after complete reassembly?.

[@obsession_engineering]

There's about 2-300ml, but no official amount of oil, as the manufacturers don't expect them to be rebuilt. It's useful to partially fill the gas bladder as you're oil filling, so it's inflated to the full size, but full pressurisation is usually done at the end

[@0x7FFFFFFFFFFF]

Really enjoying this series. I have a couple of questions! Re-building the rear shock, is there anything stopping a regular rider from doing this? I noticed you didn't show the re-gassing part, I'm guessing I need some specific equipment? For Suspension characteristics, as a lightweight, non-trackday rider of the same bike, should I consider going through the same process as you? e.g changing component internals etc, seems like you need a lot of experience with how a bike should I feel, which is experience not easily gained as a non racer. Are the the early 1000cc bikes, more fun to ride on the road than the more modern ones do you think? Thanks so much!

[@bananabrooks3836]

He has to make a living, so is not going to give away all the details.

[@obsession_engineering]

There are a few specialist tools, including a nitrogen supply at quite high pressure! So most home mechanics won't be able to do the rebuild without some extra kit, and to be fair you need to be doing it regularly to get the money back! There are also a few bits of the rebuild that are quite small in detail so difficult to film in enough detail.

[@obsession_engineering]

Oh and yes, I think some of these earlier generation bikes are as much fun, if not more fun than the latest kit. They tend to need a little more effort for the rewards, which I like. Although a new Panigale would be nice!

[@goda6369]

Sure a Panigale v4 would be awesome, but the price isnt !

[@zweiradkollektiverichkohn2916]

Nice to see one accualy going into the inside of a Kawa shock. Is the KTECH piston designed for the road or track? Does it have a manual, that gives setting alternatives according to my intended racetrack use or a altered springrate? Because I need to adapt the shock to my Suzuki SV650 racebike...

[@obsession_engineering]

They have recently updated the listing and only seem to class the piston kit as 'road' As it should be fitted by a specialist they should be able to advise spring rates and damping setup for race use

[@zweiradkollektiverichkohn2916]

How did you pull the bladder out, cause IT hast no valve thread to hold it? Im just about to do the same ktech-upgrade to mine.

[@obsession_engineering]

A bit of air pressure will ease it out nicely

[@jessefpv9217]

What sprokets did you go back with stock 17 39 or did you use the 16 in the front??

[@obsession_engineering]

17/39, stock. Tall but still plenty of go on the road

[@enxss6891]

Dave, a few questions ... How did you determine that a 9 kg/mm spring would be appropriate? Is there a formal calculation that takes into account the rider's weight, the specific bike, valves, tires, etc.? Is the rear spring that you installed now linear in its response profile? My understanding is that the typical OEM spring is non-linear to compensate for the on or off weight of a pillion rider. How does this effect valve selection? You changed the valves in both the forks and the rear shock, but only replaced the rear spring. Does there need to be any consideration for the fork springs when changing the rear spring? When choosing new valves for the forks and rear shock, if there are multiple choices, how would you determine which is best for the intended application?

[@obsession_engineering]

You can work it out by calculating the weight of bike and rider, linkage ratio, wheel travel required and load, but it gets a bit complicated. I know the stock spring weight, and have an educated decision from there. The stock spring is on the firm side, especially for a light rider on the road. The stock springs are linear rate, as are the replacements, I don't use progressive springs and it's unusual to see progressive springs on stock bikes The linkage however is non linear, on these bikes it's regressive, which is unusual, so fitting a zx6 b1h link can make them feel softer as it's more progressive. I also changed the fork springs for 9n/mm options. The valving I've used is track focused, but will work on fast road riding, as I still want the bike to behave like a sports bike, just a little softer than stock, with better damping.

[@gershwinbowers3233]

I was always told not to put a bike in gear when loosening the front sprocket nut, as it puts allot of stress on gearbox? Love to hear your thoughts on this.

[@obsession_engineering]

Once the bike is in gear it'd only be putting the same load through as riding, as the motor will turn over way before any excessive loads are applied

[@jessefpv9217]

What size is that chain. I have one chain 112 links but mines way back .

[@johnharvey5338]

I have a 2005 ZX6, is the rear shock rebuildable on that as well ?

[@obsession_engineering]

Yes, the majority of modern shocks are, and there's upgrades available for many too.

[@johnharvey5338]

@@obsession_engineering thanks, my ESA on my XR wasn’t and the price BMW wanted, over £2000, got a replacement ESA from Triactive in Holland, and it was the preload that seized and ripped the seal and it is not rebuildable, good to know, how much for a service upgrade and rebuild.

[@masterofdisaster7427]

Question, how do you get nitrogen in the bladder. I bought a new end cap with a schrader valve.

[@obsession_engineering]

There's a rubber block in the stock end, you just need a needle for your gas line

[@masterofdisaster7427]

@@obsession_engineering thanks, found fill kit on ebay.

[@TheOriginalCoda]

Is that one of those shocks that meant to be 'non-serviceable'? Or are those a different beastie?

[@obsession_engineering]

I'm not sure if Kawasaki specify them as non rebuildable, but normal main dealers wouldn't have the tooling. There are a few shocks out there that really are a pain to try and rebuild, but most can be done, and these are pretty straight forward

[@goda6369]

First Gen ZX10R was and still is legendary ! Check Out my Highway Run with that great Babe ! kzbin.info/www/bejne/nJLJiXevqMtqaZY

[@jessefpv9217]

F my bike says it was built in 11/04 do that consider it an 05 ?

[@obsession_engineering]

I'd call that 04 but not sure when khi introduced the changes. Think it was worked off engine numbers

[@jessefpv9217]

@@obsession_engineering I’m curious, as well. What changes where made between 04 05 ? Also mine doesn’t have any of the emissions stuff on it at all. None of it. Looks like it came from factory like that

[@Semmel2k]

I am literally the only one who simply custs the old chain with a cutting disc on an angle grinder? Why go through the hustle of chisseling off the link plate when you already got the grinder in your hand. Surprisingly everyone seems to do it this way anyway. Am i missing something here?

[@obsession_engineering]

I'm used to race bikes where we often alter chain lengths to suit gearing and wheel base changes, so trying to reuse as much chain as possible is a habit.

[@olliebob8359]

Are they aDunlop sportsmart tt in a 190/60 then? Il be honest it completely lost me 😂

[@obsession_engineering]

I ran the sportsmart TT in 180 but can't actually remember if it was the 55 or 60 section... Probably the 60 as that's a closer profile to the d213

[@olliebob8359]

@@obsession_engineering thanks mate, look a lovely looking tyre, I always used to swear by the sportsmart v1 but I couldn’t gel with the v2, I think il try the tt