Rear Shock quick Removal Mod.
 

If you're a lazy bastad like me and can't be bothered to strip down half your bike to get one bolt out, here's a little mod I did for future ease.

1. Remove the rear top shock nut and push the bolt through to the exhaust and cut the head off of the bolt. An air hack saw would be easiest. You could probably do this without removing anything from the rear except the rubber mudflap. I had the rear wheel off anyway which made it easier. If you don't want to buy a new bolt you can strip the exhaust off as usual and reuse the bolt and still do the mod for future ease.
http://i1200.photobucket.com/albums/...0Mod/th_18.jpg
http://i1200.photobucket.com/albums/...0Mod/th_17.jpg

2. Now push the headless bolt through so it hits the inside of the airbox. Mark it and centre punch it.
http://i1200.photobucket.com/albums/...0Mod/th_16.jpg http://i1200.photobucket.com/albums/...0Mod/th_15.jpg

3. Force a pick or something sharp through the airbox wall to mark the centre the other side.
http://i1200.photobucket.com/albums/...0Mod/th_14.jpg

4. Hole cut a 1" hole though the airbox.
http://i1200.photobucket.com/albums/...0Mod/th_13.jpg

5. Now you can remove the headless bolt through the hole you have drilled.
http://i1200.photobucket.com/albums/...0Mod/th_12.jpg http://i1200.photobucket.com/albums/...0Mod/th_11.jpg

6. This is what you're left with.
http://i1200.photobucket.com/albums/...0Mod/th_10.jpg

7. Check that your new bolt goes through easily.
http://i1200.photobucket.com/albums/...20Mod/th_7.jpg

8. Use a stanley blade or a sharp wood chisel to cut off the swarf and thin the wall of the airbox down slightly to accommodate a grommet or snap plug.
http://i1200.photobucket.com/albums/...20Mod/th_9.jpg http://i1200.photobucket.com/albums/...20Mod/th_8.jpg

9. Try your new grommet or snap plug and make sure it is secure. You need to thin down the wall of the airbox slightly to get a snug fit.
http://i1200.photobucket.com/albums/...20Mod/th_5.jpg http://i1200.photobucket.com/albums/...20Mod/th_4.jpg

10. Fit the new nut n bolt through your new access hole and torque accordingly. You can glue or seal the snap plug in place to make sure it doesn't fall out.
http://i1200.photobucket.com/albums/...20Mod/th_3.jpg http://i1200.photobucket.com/albums/...20Mod/th_2.jpg

11. Your rear shock can now be removed in minutes and without breaking all those rusty exhaust bolts. Here are the part numbers if you want new shiny bits.
http://i1200.photobucket.com/albums/...20Mod/th_1.jpg

Thats a good mod mate good pics and explanation:024:.

Good thinking mate, well done. Outside the square and very practical as long as the grommet is sealed. Nice.

Cunning plan - I like it. :thumbsup:

i did mine a couple of weeks ago and took the exhaust off - muttering the whole way about japanese design! I actually thought at the time that they shouldhave done a plug in the box!!!! great minds think alike.
i also had the mutters about the bracket the shock bolts into as the lip is placed at the bottom so its hard to get a spanner/socket on. it would have been so much easier if the strengthening part ie the lip was at the top.

nicely done.

I'm in the process of swapping my shock at the mo but have not done this mod as yet. Can I drill through my airbox before the whole process so, sort of, creating this mod in reverse order so to speak? I'm guessing Yammy just expect us to take the whole exhaust off every time this job needs doing right? This is madness, I have no knuckles left and all my neighbours have the right hump with my language :0/

Will most DIY stores sell a suitable gromet/plug type thing? Screwfix, Homebase etc?

Any guidance gratefully received.

Would these grommets do the job?

As long as the grommet is the same size as the hole saw you use and you can get the appropriate socket through the hole it will be OK. I used a 1" hole saw and 1" grommet. Just make sure you seal or glue it in place to stop any air or dust getting in. You can do the mod with or without the shock or exhaust in place. It just takes a bit of time cutting the head off the bolt (if you haven't got an air hacksaw) with the exhaust Y-piece in place.

Defo a mod for my list � I just did it 'the hard way' and that was a whole world of pain! In fact I've only just finished. The Shock swap itself was a piece of p!ss... getting to it � freaking nightmare! You practically have to take the whole rear of the bike apart. What on God's great Earth were Yamaha thinking. Come to think of it, I'm sure the rear assembly could have been simplified a fair bit too (especially with a rear rack on, that was an added pain in the Harris).

Good points though:

• It only fell of it's precarious perch once.
• I had NO unidentified bolts 'left over'
• Only ONE bolt sheered off (and I think I can probably get by without it)
• and I don't need knuckles anyway :YellowCrazy_J8GDC6:

The phrase "never again" springs to mind.

Hi there,

I wish I found this post before. I have spent two evenings setting the rear of the bike apart just to realise that not only the air box have to be removed but also the exhaust! SERIOUSLY???
They could have fit the top bolt on the shock the other way around!

Will turn the bolt around and drill the hole in the airbox. Next time there will be no pain!

Thanks for the instructions. Very clear.