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Yamaha RZ350 YPVS

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Modifications/Technical Info

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Click the Pic

 
 
 
 
FZ600 SWINGARM MODIFICATION
 
Click the swingarm to view instructions and pics of this mod-Thanks rz350land!
 
 
 
 
 

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Expansion Chamber Function--Click for Tuned Pipe Info

YPVS SYSTEM
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CYLINDER CUTAWAY--INTAKE, EXHAUST, POWER VALVES
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COOLING SYSTEM
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Click Link For RGV Swingarm Conversion Information--http://piggie.n0rks.com/

1999-2002 R6 SHOCK
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2004 R1 SHOCK MODIFICATION--Click Pic for Info
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Learn how to set-up your suspension by clicking the link below--fantastic information!

CLICK HERE TO LEARN HOW TO SET UP YOUR SUSPENSION--FRONT AND REAR!!

R6 Shock Install Instructions:

Need the following--  

  • 99-02 R6 shock (It is important that this is the shock that you use b/c it has the horizontally mounted resevoir.  Other years have a vertically mounted resevoir that ends up hitting the swingarm and does not work).

Bushings that must be pressed into the upper and lower shock mounts--these bushings can be found at McMaster Carr (See link below).  Sizes are as follows: 

  • For the upper bushings: 2x part number 6659 K36 Metric SAE 841 Bronze Flanged Bearing for 18mm shaft diameter, 22mm OD, 18mm length.
  • For the lower bushings:  2x part number 6659 K41 Metric SAE 841 Bronze Flanged Bearing for 20mm shaft diameter, 24mm OD, 16mm length.  
  1. From the R6 shock you need to remove the bushing from the top mount, and the bearing from the bottom mount.  You can bring this to a shop to press out for you, and have them press the new ones in at the same time--otherwise you can work with it on your own.
  2. Check your manual as to how to take the rear end apart in order to get the shock off so that you can put the R6 shock in--if you dont have a manual and need the information you can check the link at the bottom of these install directions,it has some info on it.
  3. You should have your bushings pressed in by this stage.  The new shock has the resevoir that interferes with the frame.  You can use a dremel or anything else that you can get to work to make room for it on the upper shock mount.  Dont be hasty!  Dremel a bit, and then do a fit check.  This is an integral point on your frame and you should leave as much of the mount as you can.  Later you should make up a bracket that bolts onto the mount, or weld one onto it in order to give the mount some integrity after you hack it a bit.  See pic below. 
  4. Once the shock fits, put the top bolt through and make sure the shock can swing far enough back so the lower linkages fit.  There will be some side to side movement of teh shock in the upper mount, make sure that when the shock is over to the left that the shock can still swing to reach the lower mounts.  Make sure you tighten the upper bolt adequately.
  5. Line up all of your suspension linkages as they were previously and put the bolt through the bottom shock mount and tighten. 
  6. The fender and the chain guard will likely need to be trimmed in order to make room for the resevoir.  Cut as much as necessary, again, keep fit testing!!  

This is not my work--I read this on the link below, and it was also posted on one of the forums--but has since been lost.  Check out the link below for some more commentary on the modification.  

Quantity

Part Number

Description

Unit Price

Total Price

Each

6659K36

Metric SAE 841 Bronze Flanged-Sleeve Bearing for 18 mm Shaft Diameter, 22 mm OD, 18 mm Length

Please enter a quantity.

$2.82 Each

$5.64

Each

6659K41

Metric SAE 841 Bronze Flanged-Sleeve Bearing for 20 mm Shaft Diameter, 24 mm OD, 16 mm Length

Please enter a quantity.

$2.79 Each

$5.58

--Click here to order Bushings--
--Click here for more detailed information--
--Click here for Pictures of this Modification!!--

UPPER SHOCK MOUNT SUPPORT BRACKET ON EACH SIDE
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F4i Shock Conversion
 
Need the following--
  • Honda F4i shock--Available very cheap on E-bay--just search "F4i shock"

Bushings that must be pressed into the lower shock mount--these bushings can be found at McMaster Carr (See link below).  Sizes are as follows: 

  • For the lower bushings:  2x part number 6658 K44--20mm shaft diameter, 24mm OD, 20mm length.  Prices and order looks like this:

Line

Quantity

Part Number

Description

Unit Price

Total Price

 

Ships

1

2
Each

6658K44

Metric SAE 841 Plain Bronze Sleeve Bearing For 20 mm Shaft Dia, 24 mm OD, 20 mm Lg

$3.43

$6.86

 

today

Merchandise

$6.86

 

 

  1. From the shock you need to remove the bearing from the bottom mount.  You can bring this to a shop to press out for you, and have them press the new bronze sleeves in at the same time--otherwise you can work with it on your own.
  2. Fit check the pin from the RZ linkages to see if you need to lightly sand/file the brass bushings.  When installed, the sleeves compress a bit and may need to be sanded a little bit.  This has been my experience on every one that I have done. 
  3. Drill out the top shock mount using a 12mm drill bit to accept the upper shock bolt from the RZ.  The existing sleeve in the top mount is large enough to be drilled out and reused.  The sleeve can remain in the shock to do this. 
  4. Check your manual as to how to take the rear end apart in order to get the shock off so that you can put the F4i shock in--if you dont have a manual...you should get one! 
  5. Reuse the RZ bolts to mount the new shock into place and re-install the rear end! 
  6. Now find a place to mount the remote resevoir--some companies make mounting brackets, or you can use hose clamps to mount it to the frame somewhere accessible for adjusting. 

I would space out the top shock mount--the F4i top mount is narrower than the stock shock.  Stock measures about 40mm, F4i measures about 28mm.  It is not likely that there will be issues if this is not done, but I am not willing to play the odds.  This can be done with washers, or cut the sleeve from the upper mount of the stock shock.  It already has the correct dimensions. 

ACCOMPANYING PICS TO FOLLOW SOON

--Click here to order Bushings--

Frame Bracing:
 
No more apologies--we now know whose pics these are!!  Stan (aka RZBeebe; Beebe) whose ride you can see on the visitor's page--or at least what it looked like when he got it.  I will be posting links to larger, more detailed pics shortly.   Bracing done with .060 steel plating.

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