The Kawi 636/GSXR/Busa Shock Install and The How to NOT cut the battery box.

[NHSVnaked]

Alright everyone,

I have done this mode with an 06 636 shock. the 04-06 are pretty much the same except for color. The Busa and GSXR have the same issues so you can use this for them as well

Here are the issues. The Stocker has a threaded bottom flange and the 636 does not. If you can get the 636 lower nut/bolt you are fine and it DOES fit between the dogbone.

As for the upper bolt you can use the stock SV upper bolt since the threaded part here is part of the frame and NOT part of the shock you are removing.

Next,
Most people complain about hacking up their battery box and how its nasty and ugly or they sit the battery on top of the shock and to me thats just not a good idea.

So here is my fix,
You must shim the untray down away from subframe there fore pushing the battery box away from the shock.

Now you may ask does this affect clearance over the tire....the answer is no.

The items needed are 2 bolts about 2" long and that have the same thread as the bolts that go into frame are ( I can not remember the thread size but go to HD or Lowes and you can match the thread).

The next item would be 2 1.5" spacers ( you can either use SS or like me use chromed plumbing pipe that I cut to size).

I also used 4 washers.

Step 1
Get everything off so you can get to the Battery Box and take out the battery.

Step 2
Unscrew the battery box/undertail where is attaches to the subframe. These are the two bolts that are CLOSEST to the battery box ( I had the whole undertray off for other reasons so I left all the other bolts holding the undertail loose doing this so it would be easier)

Step 3
Remove the Old shock and Install the 636. This will include hanging the rear end of the bike. It helps if you have someone holding the back tire so it takes the pressure off the nuts and bolts as you are removing them off the stocker. Then put the 636 in and put the bottom bolt in first then as it will be easy to just deal with the top bolt as your friend holds the back tire up again so you can do you thing.

Step 4
Since the battery box is loose put the battery in and push the battery box away from 636 and measure for your spacers. I used 1.5" but you may wanna go more or less. Be sure the battery will not rub on the shock resevoir. FYI as you sit on the bike and hit bumps the battery moves AWAY from the resevoir so you dont have to worry about that.

Step 5
Get your spacers/bolts and washers ready. As you push the battery box away from the undertail you will find out the holes in the undertail dont line up with the subframe anymore. You need to take a drill and make the holes in the untail bigger so the bolt will line up with the holes in the subframe.

Step 6
Now put your spacers bolts and washers in (the washers are needed because now that the hole is bigger in the undertail the bolt head may go through it and the spacer might come BACK through the hole so you need to be sure this will not happen sketch to follow)

Step 7
Tighten up all your undertail bolts, install battery recheck clearance and reinstall all parts.

Be sure all bolts are tight and ready to go.

Here are pics of what I did
Notice the shock/battery. Directly to the right of that you see the shiny spacer. If the directions above made no sense maybe they will now


1/16" of an inch space but as I said they dont touch.




Good luck guys. MODs please sticky this. It comes up a lot and this will save guys cutting their battery box.

With the side covers on you can barely see the spacers

[NHSVnaked]

FYI THIS MOD ONLY WORKS ON FIRST GENERATION SV'S

[enrico vespa]

ok ok, you don't have to yell

[NHSVnaked]

Oh you know me I just like to yell because I know it gets ya hot haha

[enrico vespa]

I hope this isn't a man hug moment,lol

Back to the subject, so you just put the shock in or it's always been on your bike?

[NHSVnaked]

No def not. But you made the kissy face first


I put the shock on last winter when I went from naked to fully faired

[blacktape]

does it matter if the shock touches the battery?

the reason why i ask is because i just put a gsxr shock on thet back and the reservoir touches the battery

[68T100R]

Thank you, NHSV(was)naked. This really ought to be in the FAQs where it can be readily accessed.

[NHSVnaked]

If you notice the battery box has padding in it etc so it fits tight and does not move around and if you notice in cars they are strapped down. Now I dont know for sure but I would say its best off in its battery box. I just felt safer doing it this way.

[Honda_Fan]

If I'm understanding this correctly the spacers shimmed the box down & back from stock position? I have a "busa shock to install so this looks like the way to go to keep everything unmolested.