My R1 Shock Swap - Kawasaki Versys Forum
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post #1 of 22 (permalink) Old 10-27-2013, 10:15 AM Thread Starter
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My R1 Shock Swap

I know there are many threads on people doing R1 Shock swaps.
But I thought I would give everyone a detailed, step by step process with lots of pictures to go along.

After a ton of research I opted to get a 07-08 Yamaha R1 Shock. Due to its design with all of the adjustment knobs on the outside within reach. (It is on its way to my house now) Paid $50.00 USD shipped to my house with only 3,000 miles on it. I should not need a custom spring weight made for me, because I weigh 135lbs sopping wet. The 5th or 6th preload setting should work out just fine! I rarely take and passengers.


Now there are a few options that we can go with here.

A: Local machine shop can bore out stock R1 hardware to 12mm and slap in washers to space out the shock. Janky, but it would work and be the easiest. I could have the shock mounted the day of arrival.

B: Send the R1 shock back to a friend in California and have him press out the R1 hardware and machine custom bushings for tight OEM like fit.

C: Machine spacers for the Versys frame and swing arm to reduce it from 12mm to 10mm and source new hardware. Least ideal.


Thoughts so far?
I am excited!



Hooligan
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post #2 of 22 (permalink) Old 10-27-2013, 11:56 AM
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post #3 of 22 (permalink) Old 10-28-2013, 03:35 PM
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As I mentioned in previous R1 shock threads - I used a drill press and in 1/64" steps 'opened-up' the non-hardened bushing, while I had a machine shop make up a couple of bushings for the hardened end. ONE thing to bear in mind is that our shock mounting bolts are 12mm - NOMINALLY! So, when I got my new machined-bushing in, then TRIED to put the 12mm bolt thru, I discovered that the 'shank' is slightly MORE than 12mm.

I had a choice - machine NEW 12mm bushings (think I paid around $50 for the two...), or 'work' the shank DOWN to a true 12mm, which I did, using my drill press (as a lathe...) and emery cloth to reduce its thickness.

BOTH my Vs have R1 shocks. The ride is now plush (I just rode 1621 miles between the 23rd and 26th of October - watch for a ride report...) and my butt was FINE!

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post #4 of 22 (permalink) Old 10-28-2013, 05:31 PM
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post #5 of 22 (permalink) Old 10-28-2013, 11:23 PM
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I thought i read somewhere the standard Versys bushes press into the Yamaha shock nicely.
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post #6 of 22 (permalink) Old 10-30-2013, 03:24 AM
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Quote:
Originally Posted by kiwitourer View Post
I thought i read somewhere the standard Versys bushes press into the Yamaha shock nicely.
this is interesting, could it be that a specific year model R1 is needed for the V? my previous R1 is 03 and I really like the ohlins on it.

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post #7 of 22 (permalink) Old 10-30-2013, 12:04 PM Thread Starter
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I'll have them pressed out and see if that is indeed a possibility.

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post #8 of 22 (permalink) Old 10-30-2013, 01:11 PM
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The bushings I had made to replace the hardened one are: .980"OAL x .668"OD x .468"ID. The .468 translates to 12mm which is a bit TOO tight, as the bolts have a waist that needs to be turned-down, or get the ID slightly larger.

BEST bet would to pull the top shock bolt and MEASURE its diameter, or go to a friendly Kawi dealer who has a bolt in stock and measure IT. Probably get the same results at a bolt shop on a 12mm bolt....


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post #9 of 22 (permalink) Old 10-30-2013, 02:44 PM Thread Starter
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This is excellent information!

I will present all these options and specifications to my machine shop and see what they think.

Thanks!!

Hooligan
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post #10 of 22 (permalink) Old 10-31-2013, 06:13 AM Thread Starter
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Quote:
Originally Posted by jdrocks View Post
how is it that your machine shop has time to turn a new bushing, but no time to bore the R1?

My friend in california is going to turn the bushing for me if need be.

Boring the R1 shock is time consuming.... But I'll check with my local shop when the shock gets in.

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Last edited by Freerydejunky; 10-31-2013 at 06:24 AM.
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post #11 of 22 (permalink) Old 10-31-2013, 06:24 AM Thread Starter
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Shock should be here on the 8th.

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post #12 of 22 (permalink) Old 10-31-2013, 01:23 PM
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Originally Posted by jdrocks View Post
how is it that your machine shop has time to turn a new bushing, but no time to bore the R1?
The machine shop I used in Kelowna didn't WANT to bore a hardened bushing, but suggested making two for me, Dave. As for the other bushing - did it myself on my drill-press, 1/64" at a time....

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post #13 of 22 (permalink) Old 10-31-2013, 03:05 PM Thread Starter
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$50 Shipped.
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post #14 of 22 (permalink) Old 11-06-2013, 07:57 PM Thread Starter
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Got the shock back from the machine shop today. 60 bucks for a new steel sleeve bushing made. The other eyelet drilled.

5mm of spacers/washers installed on the top. 2mm washers installed on the bottom. Tightened down and put back together.

Since I am a scant 135lbs soaking wet I am able to get a way with the stock spring. It is on the 8th preload setting with low speed compression 4 clicks in. 1 turn full high speed. Its still a but wallowie and sits a bit low, it'll probably get more low speed soon.

But instantly the ride is soooo much better. Well worth the upgrade! Best 110 bucks you can spend on the V if you are a lighter guy.
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Last edited by Freerydejunky; 11-07-2013 at 12:55 PM.
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post #15 of 22 (permalink) Old 11-07-2013, 11:06 AM
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...Well worth the upgrade! Best 110 bucks you can spend on the V if you are a lighter guy.
Or a bit more $, if you're a HEAVIER guy!!!

Ed
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post #16 of 22 (permalink) Old 11-07-2013, 12:55 PM Thread Starter
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I've backed it down to the 7th spring setting. Still 4 clicks low speed and one turn high speed.

Hooligan
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post #17 of 22 (permalink) Old 07-04-2014, 10:36 AM Thread Starter
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Recently took the R1 shock off due to doing a ton of 2up riding. The 9kg spring couldn't handle it.

Got a roadstar spring in the mail a few weeks back, life has been getting in the way of putting it on though... Hopefully the R1 shock will be back on here shortly.

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post #18 of 22 (permalink) Old 07-04-2014, 01:33 PM
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Originally Posted by Freerydejunky View Post
Recently took the R1 shock off due to doing a ton of 2up riding. The 9kg spring couldn't handle it.

Got a roadstar spring in the mail a few weeks back, life has been getting in the way of putting it on though... Hopefully the R1 shock will be back on here shortly.
How much do you weigh...? I have 13.8 kg/mm springs on both my R1 shocks, and I'm 180# 'soaking-wet' so 195# 'suited-up'. I occasionally have a pillion passenger who weighs about 120#, and that shock works fine for me.

Ed
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post #19 of 22 (permalink) Old 07-04-2014, 08:25 PM Thread Starter
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I am 135 nekkid. So 150 wish with gear.
Rarely do I ever ride without a topcase full of books or school supplies. So add an extra 10-15lbs

Since I only own a motorcycle, my girl friend rides with me at least twice a week for an hour or two.

I have the Roadstar sprig I'll get it a shot and go from there.

Hooligan
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post #20 of 22 (permalink) Old 07-05-2014, 05:10 AM
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Originally Posted by fasteddiecopeman View Post
How much do you weigh...? I have 13.8 kg/mm springs on both my R1 shocks, and I'm 180# 'soaking-wet' so 195# 'suited-up'. I occasionally have a pillion passenger who weighs about 120#, and that shock works fine for me.
Aren't your 13.8 mm/kg (773 lb/in) springs custom made? That is of course why you have adequate support, even though it's an R1 shock.

At 208 lbs net, I too am quite satisfied with my 800 lb/in (14.29 kg/mm) spring which came standard with my $100 China shock with remote reservoir... Huge improvement over stock shock's 940 lb/in (16.79 kg/mm) spring.

Last edited by invader; 07-05-2014 at 05:30 AM.
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