400EX Shock Install
By Jeremy at BlasterRiders
obviously remove the old shock
drill out lower shock mount(on shock) to pin dimensions..i dont have the size off hand but youll have the pin in your hand.
fab a spacer for the lower shock mount to fill the gap where the stock linkage went. steel tubing works well here.
youll have to cut the front of the airbox to fit the rezzie...see pic, i'll update with finished airbox pics when i fab a plate to fill the gap i cut.
youll need to drill out the ex upper bearing sleeve to the dimensions of the upper bolt...once again, youll have the bolt in hand.
use washers stacked to evenly space shock in upper mount.
i put one on mine today...one word..AWESOME!!!!. i cant explain how great this shock feels, i'm speechless, with a little work..you can do it yourself also.
ok...i "attemted to drill out the upper bearing sleeve to accept the stock 14mm bolt...NO WAY!!!! its case hardened steel, so, yes, it does have a bearing sleeve...heres the fix, 2.00 at a hardware store. they have bronze bearing sleeves, various sizes, you need to get a 1.5" long x 9/16" o.d. x 1/2" i.d., youll have to put the bushing in a drill...put a bolt through the bushing, put a nut on the other end...snug it up and put the threaded remainder in the drill. while running the drill using a file..wide file, file the bushing down to .690-.680" youll need a dial caliper or a micrometer for this part..it is a precision fit...instead of using the stock 14mm bolt, use a 1/2 x 2.5" in its place, place 2 1/2" flat washers on each side of the top mount...tighten down as tight as possible to squeeze the mounting tabs against the washers...your done.
bottom...just drill the shock holes to 12mm or use a dremel with a grinding bit like i did until the pin fits through snugly. i used stacked washers as a spacer for the meantime till i get around to making one for it.
my bronze spacer..top bearing sleeve
drill out lower shock mount(on shock) to pin dimensions..i dont have the size off hand but youll have the pin in your hand.
fab a spacer for the lower shock mount to fill the gap where the stock linkage went. steel tubing works well here.
youll have to cut the front of the airbox to fit the rezzie...see pic, i'll update with finished airbox pics when i fab a plate to fill the gap i cut.
youll need to drill out the ex upper bearing sleeve to the dimensions of the upper bolt...once again, youll have the bolt in hand.
use washers stacked to evenly space shock in upper mount.
i put one on mine today...one word..AWESOME!!!!. i cant explain how great this shock feels, i'm speechless, with a little work..you can do it yourself also.
ok...i "attemted to drill out the upper bearing sleeve to accept the stock 14mm bolt...NO WAY!!!! its case hardened steel, so, yes, it does have a bearing sleeve...heres the fix, 2.00 at a hardware store. they have bronze bearing sleeves, various sizes, you need to get a 1.5" long x 9/16" o.d. x 1/2" i.d., youll have to put the bushing in a drill...put a bolt through the bushing, put a nut on the other end...snug it up and put the threaded remainder in the drill. while running the drill using a file..wide file, file the bushing down to .690-.680" youll need a dial caliper or a micrometer for this part..it is a precision fit...instead of using the stock 14mm bolt, use a 1/2 x 2.5" in its place, place 2 1/2" flat washers on each side of the top mount...tighten down as tight as possible to squeeze the mounting tabs against the washers...your done.
bottom...just drill the shock holes to 12mm or use a dremel with a grinding bit like i did until the pin fits through snugly. i used stacked washers as a spacer for the meantime till i get around to making one for it.
my bronze spacer..top bearing sleeve