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NOTE: Please Read All the Thread
and The End for Important Info. Before Attempting to Complete Mod.

Instructions For Completing the R6 Rear Shock Mod:

Materials needed:

1. 2004 R6 Rear Shock w/top linkage bolt and nut (other years may be
used as long as reservior runs down the lenth of the shock and not
horizontal, like on older ones)

2. Cutting Tool (anything used to be able to cut through aluminum) I
used a air compressor and die grinder w/ cutting tip.

3. Can of Primer and Aluminum Colored Paint (Optional-to touch up part
that is cut)

4. Small 2x4 or similiar to hold up tire when shock is removed.

5. File Set (optional, to smooth out rough edges on cuts)

Step One:

Place Bike on Rear Stand and Remove Seat. After removing seat
also remove both side covers (labeled FZ6).

Step Two:

Remove tire hugger w/10mm wrench or socket, 4 bolts-two on left
and two on right, there is a plastic rivet on the front of the hugger to
remove push in the dot in the center and it'll pop up.

Step Three:

Remove FZ6 shock. Start with lower, will need a 14mm wrench and
socket(wrench to hold nut and use socket to loosen and remove bolt,
CAUTION: tire and swingarm may fall away to ground place 2x4 underneath
for support.

Now use 14mm socket and loosen and remove nut on the left side of bike
for the top of the FZ6 shock, after removing bolt push bolt out through
the other side (remember to hold shock so it doesnt fall out). Once
unbolted you will have to manuver it out. Once shock is out you can
pull 2x4 out from underneath to let the tire settle to the ground which
will give you some extra working clearance.



Unhook Trunk lock cable from catch in the undertray and move aside (don't

not forget to reattached when finished or you'll be locked out of the
underseat storage) Remove undertray- two bolts at the back one
on the front right of tray and one on the left side right above the lock
cylinder for the storage. (Tray will take some twisting and effort to
remove!)

Step Four:

Now for the not so faint at heart! Cutting time; taking cutting
tool and remove excess material from the top shock mount as shown as
colored area on Before Cutting Mount pictured below, after cutting it
should look like the second Picture below.
This will allow room for the top of the shock mount where the
reservior's oil passages come out (cutting this exactly as shown allows
for clearance even with suspension in play)

You can use the paint here to coat the exposed aluminum where it was cut
to prevent from rusting (is optional; but a good idea nonetheless)

Step Six:
Now you will have to cut the undertray to make room for the
reservior that will extend out back. You will have to cut as shown in
Undertray Picture below. Best method is to take measurements of
width and
depth and cut. I did it by eye, but not everyone can do that so its up
to you. After thats done put the undertray back in it's place and bolt
on; DONT FORGET: to reconnect the cable for the lock, I can not stress
it enough!

Step Seven:
After that you will now need to cut the tire hugger. You only
have to cut out the space behind the reservior so that it wont come into
contact with it when the suspension travels. Cut as shown on Cutting

Hugger Picture below. I opted to do away with my hugger as I saw
another member
here do and liked the outcome. Again it comes to personal preference.
After cutting enough space for reservior check with hugger back on and
bounce the susp. so that you verify clearance, if not you'll have to
remove it all over again and cut some more; once done bolt hugger back
on and on the plastic rivet push the thing in the middle up through the
base and you can snap it back into the swing arm, once in place you can
know push the thing in the middle back down to secure it. Wah Lah all
finished!

Finihed Picture below

PLEASE READ THE FOLLOWING BEFORE ATTEMPTING TO DO MOD:

The R6 spring is smaller than the FZ6
spring by almost 1/2 an inch;
which means that the rear will be lowered. I have lowered the front
some through the triples to match front/rear. One other thing that I
noticed is that even on the highest preload the R6 shock is as soft as
my FZ shock on the #4 setting because it is now under direct forces (ei:
up and down from mount to mount instead of movement through linkage).
The spring doesnt need to be as stiff as the one on our bike so the last
thing to complete this mod is to take the spring off of the FZ6 shock
and replace it with the spring of the R6 shock; this will retain ride
height, original preload, but still have adjustability. ( I am saving
this for another day because it will require a spring compressor and
more time, I just wanted to get the hard part out of the way) Some of
you may say wait but the piston rod of the R6 shock is shorter so it
won't work, my thinking is that its shorter by 3/8's of an inch so
putting on the FZ spring won't pull it out that far, plus accounting for
the adjusting the preload and rider weight will compress the rod enough
for the shock valve to be in effiecient operating zone.

All credit for this mod
must go to user : jesfz6r
from sportbikes.net