ZX 6 swingarm swap

[Gearhead119]

I know this is a popular mod on the zrx and alot of guys ask alot of the same questions. I thought I would post up some pics and details of what is required to make one of these fit. It is really quite simple. I currently have one of these on my bike but it is +6 over and I'd like to have a stockish length arm for playin around with... so here ya go.

This arm is off a 03-04 zx6. I picked it up from another member here and it came complete with the axle, blocks, linkage, caliper, bracket, MC, basically everything but the wheel. I already run the zx6 wheel so this should be simple.

First step. unbolted the linkage. it's getting cleaned up of any extra tabs and BS that the zx used. I chose to use the stock dual shocks.... so the linkage mount got milled off. everything smoothed out and you can't tell it was ever there. the top side had a hugger mount as well.... those came off as well. I am going to leave the chain guard mounting tabs for now. I don't know if the stock guard I have will be close but it's easy to cut them off later than to remake them. here's a few pics


You don't HAVE to remove the linkage mount, as it's on the bottom of the arm and isn't really in the way, but I like the " should have been factory" look. the hugger mounts (atleast the center ones) will be VERY close to the under side of the stock storage compartment. I've already modified mine for the longer arm but those with stockers will notice a close clarence.

next the roller bearing and pivot bushing are removed and the rex one is going in it's place. I belive there is a spacer that is going to be reused from the rex as well. The needle bearings will be replaced when I'm all done as they have to come out to get it PC'd but for mock up... they will be fine.


so far that is all I got... more to come.....

[Geoffery86]

[Dead Roman]

So when we gonna get more of this Gearhead?

[Gearhead119]

I need to get the forks finished up before I can finish the swingarm. I'm not sure where the shock mounts will locate yet.. I need to get the correct ride height/ steering angles. I'm trying to get the tank finished as well... at least mocked up. If I start bouncin around too much I'll never get things finished.... Really the shock mounts are all that are needed to get this thing into service. These are as close to a "bolt in" swap as you get when it comes to swingarms (unless its made specifically for a rex). I'll get some more pics when I make more progress..

[Geoffery86]

I started putting mine on today and he is not lying its super easy gearhead the pivot bearing and the roller bearing do the have to be changed what is the difference

[Gearhead119]

only the roller bearing needs swapped I believe... the needle bearings are fine. the pivot bushing has a smaller i.d. for the rex as well as the spacers that sit in the seals ... I think the roller needs swaped so the spacers fit... . It's really easy to see when you put it together.

[schmoo]

Happy Birthday Eric, I was almost too late .

[1100Z]

personally I like the stock Rex swingarm, but very interested to see hoe this turns out!

[Gearhead119]

Happy Birthday Eric, I was almost too late .

Thanks Schmoo

personally I like the stock Rex swingarm, but very interested to see hoe this turns out!

I would agree... I do like the look of the stocker... especially a braced one... but from performance standpoint... the zx arm has more potential to handle the added power. And I've already done the swap... I'm just goin back to a stock length one rather than +6.

[1100Z]

Speaking of......... I am still pretty green to the ZRX world and the last search I did for the ZRX swingarm bracing and the last posts seemed to date back to 09. Does anybody still do this??? I was kinda hoping to do this to mine at somepoint, I really like the ones I have seen!

[oldkawboy]

Don't mean to hijack the thread but since it's kinda related.......

I have an '03 ZX6R swingarm, rear wheel, rotor, cushdrive & sprocket that is all in great shape that I bought a couple years ago to do the conversion but never got around to it due to too many other projects.

If anyone is interested in doing this cool project drop me a PM and we'll talk.

Dan

(Back to your scheduled program)

[Downunder]

Hello Gearhead

There are a few people hanging out for a good writeup on this mod.

I've read all the threads on topic - but no-one has gone into much detail.

I appreciate you're a busy chap - but if you could finish off the writeup it would be a great help.

I would look to use the 2004 ZX6r arm.

I would use the ZX6 wheel/cush/rotor/disk so its just the frame end of the mod I'm interested in - although others may have different interests.

Thanks in advance.

[SteddyTeddy]

Not a whole lot more to write up. You will use the seal and spacer on the right side from the ZRX swing arm. On the left side I used the cap from the ZX6, part # 11012-1658. Basicly a big washer of sorts. I had to sand it down some as it was a tight fit into the frame. You can use the stock pivot bolt but it is a few .001" loose in the ZX sleave. Most make or modify a new pivot bolt to tighten it up. I had a ZX6 pivot bolt modified to work. Last you will need to flip your front sprocket over as the chain alignment will now be 5mm toward the outside of the bike.

[kajunzrex]

[Gearhead119]

Ok... Here's where we are at right now on the zx6 arm.

I decided to try something a little different with the shock mounts.. It's hard to make a double mount (2 diff. holes) that works with the stock shocks. the adjuster on the shock hits the front mount when you try to use the rear mounting hole... so why not make the whole mount movable. They use adjustable stuff on some of the fancy arms from Japan so why not try something (maybe not as fancy) similar.

This is What I scetched up on windows paint.. just for ideas..


Then It was get a chunk of Alloy and try to make it for real.. I picked up some 1.25"x 3"x 12" (I think.. ) off ebay . It is 6061.
Here is What I have so far.. still a ways to go but it's kinda taking shape now.



I offset the mounting hole for more adjustability. the blocks will be reversable for finer tuning.


more to come........

[kajunzrex]

This guy is friggin brilliant

[paulzrx]

Ok... Here's where we are at right now on the zx6 arm.

I decided to try something a little different with the shock mounts.. It's hard to make a double mount (2 diff. holes) that works with the stock shocks. the adjuster on the shock hits the front mount when you try to use the rear mounting hole... so why not make the whole mount movable. They use adjustable stuff on some of the fancy arms from Japan so why not try something (maybe not as fancy) similar.

This is What I scetched up on windows paint.. just for ideas..


Then It was get a chunk of Alloy and try to make it for real.. I picked up some 1.25"x 3"x 12" (I think.. ) off ebay . It is 6061.
Here is What I have so far.. still a ways to go but it's kinda taking shape now.



I offset the mounting hole for more adjustability. the blocks will be reversable for finer tuning.


more to come........

WOW, How sweet is this....WTG....

[Gearhead119]

This guy is friggin brilliant

I've been called many things..... friggin brilliant isn't one of them

I just have a couple old tools to play with at work. old school stuff thats built so tough it would be hard to break'em. and a fancy machine that can melt it all back together

[Dead Roman]

I like it. Adjustable shock mounts is a pretty slick idea.

[kajunzrex]

[Gearhead119]

I got lots of pics to post .. here's where It's at now..

[Gearhead119]

Finally got the sprockets lined up.. had to machine down the cushdrive hub and space the front out a little. you can see there is very little room between the right side of the tire and the arm... I've cheated it over as far as I could. the tire is just a little off center to the right but theres only so much room to play with. this is a 6.5" wheel made for a zx10. I've take as much off the cush drive as I feel comfortable doing.

[Gearhead119]

zx6 pivot vs. zrx (all steel) the light one is a tad shorter too..





I've already shortened the storage compartment an inch... I believe itwill clear at the stock ride height without doing this mod.. If you want to stretch it and slam it.. it hits...

[schmoo]

Nice work Eric . I bet you have a lot of time invested in that mod. I like the adjustable shock mounts , looks trick.

[Gearhead119]

Yes It is taking me quite a while to just find time to work on it... Thankfully Theo is being patient.. sad to say I will not be the one reaping the benefits of this mod. Theo has been sending parts my way and I'm makin them fit together. It is getting a trick brembo caliper and one off hanger as well as some more underbracing...

[kajunzrex]

Leave that tire on when you send everything to me....there's still some tread in the edges

[Gearhead119]

It really does have quite a bit left! Not sure if I'd be draggin a knee with it. It's pretty old... some squid left it at our shop a few years ago... its a 190/50 (or 55?) can't remember... works good for mock up and burnouts.

[kajunzrex]

Yes It is taking me quite a while to just find time to work on it... Thankfully Theo is being patient.. sad to say I will not be the one reaping the benefits of this mod. Theo has been sending parts my way and I'm makin them fit together. It is getting a trick brembo caliper and one off hanger as well as some more underbracing...

Im in no rush brother but I cant wait to have that nice stiff arm.....was reminded today how flexy the stock arm is in 100mph+ sweepers

[Gearhead119]

I've been spending some time at the mill making a big chunk of aluminum into a little chunk. I have most of the structural areas squared away.. now I got to start getting rid of the extra crap and make it pretty and light. The "ears" that the caliper mount on will be the last part as I need a big flat surface to clamp onto..



Here is the new one next to the stock zx6 bracket.. It will (hopefully) be able to use the stock zx locating tab on the arm. lots of finish work to make it fit right though.

[kajunzrex]

Ladies and gents.....this is how is born