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Originally Posted by ApparitionAGO
OK, I am going to ask a lot at once, so take it easy on me!
First, I am staring in semi-despair at my track body work (Armour bodies, if that matters) and the bike. Any hints on mounting it? My biggest question is wtf to do with the places where the stock body work has a pressure fit stud. What do I do to mount the aftermarket stuff to those places? Other than measure 3 times, drill once, and use patience, anything else I should know?
Secondly, I just ordered an Ohlins rear shock. One day at the track on my bike/barcalounger convinced me that stock suspension had to go. Budget didnt include a kit for the front yet, but the rear is gone, and so is the damper. So how hard is it to mount the rear? Just how much do I need to pull apart to get at it? Any tricks I should know that will make it extraordinarily easy?  In the grand scheme of things I am not too worried, I am armed with a set of tools, a shop manual, and 2 weeks until the next track day, but any help or guidance you could give would be hugely appreciated... 
I am editing because I already forgot: the front fender only really comes off when the front tire does, right? And what do I do with the electrical sensor after the kickstand comes off? Help me o wise one, please! |
Bodywork is not hard to mount. Take your time and get a friend to help. Go to Lowes or Home Depot and buy a uni bit makes drilling easier. Use the OEM rubber gromets in the holes where necessary.
Rear shock can be installed once you support the bike through the swingarm pivot (nice long thin steel rod works great on jack stands) or hang the bike by the subframe overheard. Be sure to grease the link/shock pivot areas since they come with very little if any grease from the factory, bel-ray water proof works best. Re-torque to factory specs a shop manual helps with this.
On '05 and prior models (I have not looked closely at a '06 but I bet its similar) all you had to do on a kickstand removal/swithc disable was either cut the connector and twist the two wires together or do like I do and go to the Suzuki dealer and get the female brass OEM connectors join them with a piece of electricla wire and plug this into the connector on the bike, no more switch activity since it is wired open now.
Front fender can only be removed after front wheel is off, unbolt it completely lift up on it turn it 90 degrees and slide it down the fork tubes.