03-04 ZX6RR 636 Installation Instructions for:
Frame Sliders
Fork Sliders
Bar Ends
Swingarm Spools
WARNING: The installation of all parts in these installation instructions must be performed by a qualified motorcycle mechanic who is using the correct tools and who understands the correct use of all tools required to complete the installation.
Tools you will need:
Torque wrench
6mm Hex/Allen driver
8mm Hex/Allen driver
Ratchet and extension
Frame Sliders
Fairings do not need to be modified in any way or removed from the bike to install our frame sliders set.
If you damage a slider in a crash or drop, you can replace the slider you need without purchasing the set by ordering from our website, www.oesaccessories.com.
Frame Sliders
Fork Sliders
Bar Ends
Swingarm Spools
WARNING: The installation of all parts in these installation instructions must be performed by a qualified motorcycle mechanic who is using the correct tools and who understands the correct use of all tools required to complete the installation.
Tools you will need:
Torque wrench
6mm Hex/Allen driver
8mm Hex/Allen driver
Ratchet and extension
Frame Sliders
Fairings do not need to be modified in any way or removed from the bike to install our frame sliders set.
- Remove the left side engine mount bolt (circled in red) with the 6mm hex driver. The bolt has a nut on the back side which is held in place so you won’t need to hold it with a wrench, but you will need to be ready to catch it when it falls out of place as it is to be replaced with the supplied Nyloc nut.
- After you have retrieved the factory nut, install the supplied Nyloc nut in the recess in the engine mount bolt hole. This may prove to be the hardest part of the installation due to access, but keep trying, you’ll get it. You will notice the nut has a plastic insert in it. This is the locking part of the nut and the bolt will not thread into this portion first, so be sure to install the nut with the plastic part facing the inside of the bike. WARNING: THE WASHER MUST BE ON THE SCREW BEFORE INSTALLING THE SLIDERS
- Now you can install the left side frame slider. The left side slider is the longest of the two. Hold the Nyloc nut in place and start threading the bolt into place. After the bolt starts threading into the nut, pull outward on the frame slider while continuing to tighten the bolt; this will keep the nut in place until the bolt is tight. Some normal resistance will occur once the screw starts threading into the locking section of the nut. Tighten the bolt to the factory torque specification (same as factory bolt).
- On the right side you will see a castle-type nut on a large stud. This is the lock nut for the engine mount adjuster and does not need to be loosened. At a glance, it may appear that the engine mount bolt and the stud are one. The stud is hollow and the engine mount bolt runs through it. Remove the bolt with your 6mm hex driver remembering to retrieve the nut on the backside of the bolt from the inset.
- Repeat the steps used on the left side of the bike to complete the installation.
If you damage a slider in a crash or drop, you can replace the slider you need without purchasing the set by ordering from our website, www.oesaccessories.com.
Fork Sliders
Note: This set is installed with the front axle in its normal operating position.
1. Apply medium strength thread locker compound (available here) to the supplied mounting screw being sure that the washer is on the screw.
2. Install one of the axle sliders onto the supplied shaft and lightly tighten with a 5mm hex wrench.
3. Insert slider and shaft assembly into the axle.
4. Apply medium thread locker compound to the remaining screw and insert through the remaining slider. While holding the
opposing slider/shaft firmly in place by hand, insert the slider/screw into the axle and carefully start the screw into
the shaft. It may take some careful positioning of the shaft to get the screw threads started into the shaft.
5. Once the screw has been started and confirmed that proper thread engagement was made, lightly torque the
screw.
6. Final tighten the opposing screw with light torque.
Important: Do not over tighten the left or right side screw.
For technical assistance, please contact us
Swingarm Spools
The spools are side-specific for this model.
Apply a small amount of medium strength (blue threadlocker) to the threads of the supplied screws. Install each with 5 lb/ft of torque.
Bar Ends
1. Apply a small amount of medium strength thread locker (Loctite) to the threads of supplied screws.
2. Install each side with light torque.
3. Warning! Ensure that there is no interference between the right side bar grip and the bar end that would inhibit smooth throttle action.
Note: This set is installed with the front axle in its normal operating position.
1. Apply medium strength thread locker compound (available here) to the supplied mounting screw being sure that the washer is on the screw.
2. Install one of the axle sliders onto the supplied shaft and lightly tighten with a 5mm hex wrench.
3. Insert slider and shaft assembly into the axle.
4. Apply medium thread locker compound to the remaining screw and insert through the remaining slider. While holding the
opposing slider/shaft firmly in place by hand, insert the slider/screw into the axle and carefully start the screw into
the shaft. It may take some careful positioning of the shaft to get the screw threads started into the shaft.
5. Once the screw has been started and confirmed that proper thread engagement was made, lightly torque the
screw.
6. Final tighten the opposing screw with light torque.
Important: Do not over tighten the left or right side screw.
For technical assistance, please contact us
Swingarm Spools
The spools are side-specific for this model.
Apply a small amount of medium strength (blue threadlocker) to the threads of the supplied screws. Install each with 5 lb/ft of torque.
Bar Ends
1. Apply a small amount of medium strength thread locker (Loctite) to the threads of supplied screws.
2. Install each side with light torque.
3. Warning! Ensure that there is no interference between the right side bar grip and the bar end that would inhibit smooth throttle action.