03-06 600RR Installation Instructions for:
Frame Sliders
Bar Ends
Swingarm Spools
Fork Sliders (05-06 only)
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.
Frame Sliders
Note: The instructions are based on using the special alignment tool available on our
website, however, the tool does not necessarily need to be used.
Part I: Cutting the Holes
1) Remove the right side mid fairing, disconnecting it from the lower and upper cowl.
2) Place the alignment tool into the hexagonal shaped bolt head of the right, forward engine mount- this is where the
slider will be attached. The sharp point of the alignment tool should be facing outward and the tool should have no
lateral movement.
3) Estimate where the frame slider hole will be in the fairing and cut out a three-inch piece of the foam strip that is
glued onto the inside of the fairing- this will enable you to make a mark on the inside of the fairing with the alignment
tool.
4) With the alignment tool in place, re-attach the fairing to the bike using at least three of the body screws. Make
certain that the fairing is securely and precisely attached to the bike.
5) Press firmly on the fairing in the area of the tool to achieve a mark on the inside of the fairing. This mark is the
center of the frame slider hole.
6) Remove the fairing again. You are now ready to cut the hole in your fairing for the slider.
7) Select a hole saw that is ¼” bigger in diameter than the size of the slider and has a small pilot drill bit in it.
8) Begin the cut by placing the tip of the drill bit on the mark made by the alignment tool and drilling through the
plastic. At this point it is advisable to place the fairing back on the bike and insure the pilot hole is center with the
engine mount bolt head. If so, you may now use the hole saw to cut through the plastic.
9) The procedure for cutting the hole in the left fairing is the same except for one point: The engine mount screw
must be broken loose and backed out enough for the tool to make contact with the inside of the fairing. The tool will
be placed in the hole that goes through the center of the bolt.
Part II: Installing the Sliders
1) Remove the nut on the backside of the engine mount bolt using the closed end of a 17mm wrench.
2) Loosen the pinch bolt on the frame and push the bolt out of the hole. If the bolt does not slide out easily it may be
necessary to support the engine with a hydraulic jack. Place the jack under the oil pan using a piece of wood or
rubber mat between the jack and the oil pan.
Note: An aluminum spacer that lies between the engine and frame could fall out of place, but should easily slide
back into place. Do not omit this spacer when installing the right slider.
WARNING: THE WASHER MUST BE ON THE SCREW BEFORE INSTALLING THE SLIDERS
3) The shorter slider of the set goes on the right side of the bike. The aluminum sleeve will go inside the frame
under the pinch bolt. Place the slider and bolt with the sleeve into the engine mount hole, making certain the
aluminum spacer mentioned in step 2 is in place.
4) Thread the factory 17mm nut back onto the new bolt, hold the nut on the back side with a wrench, and initially tighten the bolt with moderate force.
5) Tighten the pinch bolt using a torque wrench set at the factory specified amount of torque.
6) Hold the nut on the back side of the engine mount bolt and final tighten the engine mount bolt using a torque wrench set at the factory specified amount of torque. (same as factory screw)
7) On the left side, you must simply remove the engine mount bolt and install the remaining slider using the provided
bolt. Be certain not to cross the threads or over-torque the bolt. DO NOT USE A BREAKER-BAR TO TIGHTEN THE BOLT. TIGHTEN TO THE FACTORY TORQUE SPECIFICATION USING A TORQUE WRENCH.
6) At this point the fairings can be replaced on the bike.
If you have any questions about this process please feel free to contact us.
Bar Ends
1. Remove the existing bar ends.
The inside of the bar should have a notched insert that matches the shape of the base of the bar end; our bar ends are made to fit a factory setup and will not work with a generic insert or any type of aftermarket race clip-on bars.
2. Apply a small amount of blue or red thread locker (Loctite) to the supplied screws.
3. Install the bar end making sure that the bar end notch is correctly mated to the bar insert and add light torque with a 5mm Allen wrench. If the bar end appears crooked it may indicate that the notch on the bar end and bar insert are not aligned correctly.
4. Confirm that the bar grip on the throttle side does not touch the bar end and that the bar end does not inhibit smooth throttle twisting action in any way.
Fork Sliders
Items/tools needed:
Torque wrench
22mm socket
Ratchet
5mm Allen wrench
Blue and red Loctite
Our fork sliders are designed to work with the factory axle assembly and do not replace the factory axle or modify the factory axle mounting position. However, the kit does replace the factory axle bolt with our special mounting bolt.
This set will only fit the 2005-2006 600RR which came standard with inverted forks.
1. Remove the factory axle bolt with your 22mm socket/ratchet. Do not loosen or remove any other bolts.
2. Install and tighten the axle bolt that is supplied with the fork sliders kit. Use a torque wrench set to the factory specified amount of torque.
3. Use red Loctite on the supplied screw for the left side fork slider and attach the slider to the aluminum rod in the kit. The left axle slider has an extended base that is designed to fit into the axle.
4. Add blue Loctite to the threads of the right side fork slider screw and insert through the axle slider. The right side axle slider is cupped in a way that covers the bolt head when installed correctly.
5. Insert the left side axle slider/rod assembly into the left side of the axle and hold firmly in place.
6. Add the right side axle slider by inserting the screw through the hole in the OES supplied axle bolt and tightening onto the connecting rod. Once started, the screw should thread into the rod easily.
7. Use light torque to tighten the screws- if the left side turns you can hold it with another wrench.
Warning! Do not over tighten- the threads in the connecting rod will strip if too much force is used. A new rod can be purchased if the threads are damaged.
Swingarm Spools
Add a small amount of blue thread locker (Loctite) to the supplied screws and tighten with a light amount of torque using a 6mm Allen wrench.
We will be more than happy to provide customer support if needed- please contact us.
Frame Sliders
Bar Ends
Swingarm Spools
Fork Sliders (05-06 only)
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.
Frame Sliders
Note: The instructions are based on using the special alignment tool available on our
website, however, the tool does not necessarily need to be used.
Part I: Cutting the Holes
1) Remove the right side mid fairing, disconnecting it from the lower and upper cowl.
2) Place the alignment tool into the hexagonal shaped bolt head of the right, forward engine mount- this is where the
slider will be attached. The sharp point of the alignment tool should be facing outward and the tool should have no
lateral movement.
3) Estimate where the frame slider hole will be in the fairing and cut out a three-inch piece of the foam strip that is
glued onto the inside of the fairing- this will enable you to make a mark on the inside of the fairing with the alignment
tool.
4) With the alignment tool in place, re-attach the fairing to the bike using at least three of the body screws. Make
certain that the fairing is securely and precisely attached to the bike.
5) Press firmly on the fairing in the area of the tool to achieve a mark on the inside of the fairing. This mark is the
center of the frame slider hole.
6) Remove the fairing again. You are now ready to cut the hole in your fairing for the slider.
7) Select a hole saw that is ¼” bigger in diameter than the size of the slider and has a small pilot drill bit in it.
8) Begin the cut by placing the tip of the drill bit on the mark made by the alignment tool and drilling through the
plastic. At this point it is advisable to place the fairing back on the bike and insure the pilot hole is center with the
engine mount bolt head. If so, you may now use the hole saw to cut through the plastic.
9) The procedure for cutting the hole in the left fairing is the same except for one point: The engine mount screw
must be broken loose and backed out enough for the tool to make contact with the inside of the fairing. The tool will
be placed in the hole that goes through the center of the bolt.
Part II: Installing the Sliders
1) Remove the nut on the backside of the engine mount bolt using the closed end of a 17mm wrench.
2) Loosen the pinch bolt on the frame and push the bolt out of the hole. If the bolt does not slide out easily it may be
necessary to support the engine with a hydraulic jack. Place the jack under the oil pan using a piece of wood or
rubber mat between the jack and the oil pan.
Note: An aluminum spacer that lies between the engine and frame could fall out of place, but should easily slide
back into place. Do not omit this spacer when installing the right slider.
WARNING: THE WASHER MUST BE ON THE SCREW BEFORE INSTALLING THE SLIDERS
3) The shorter slider of the set goes on the right side of the bike. The aluminum sleeve will go inside the frame
under the pinch bolt. Place the slider and bolt with the sleeve into the engine mount hole, making certain the
aluminum spacer mentioned in step 2 is in place.
4) Thread the factory 17mm nut back onto the new bolt, hold the nut on the back side with a wrench, and initially tighten the bolt with moderate force.
5) Tighten the pinch bolt using a torque wrench set at the factory specified amount of torque.
6) Hold the nut on the back side of the engine mount bolt and final tighten the engine mount bolt using a torque wrench set at the factory specified amount of torque. (same as factory screw)
7) On the left side, you must simply remove the engine mount bolt and install the remaining slider using the provided
bolt. Be certain not to cross the threads or over-torque the bolt. DO NOT USE A BREAKER-BAR TO TIGHTEN THE BOLT. TIGHTEN TO THE FACTORY TORQUE SPECIFICATION USING A TORQUE WRENCH.
6) At this point the fairings can be replaced on the bike.
If you have any questions about this process please feel free to contact us.
Bar Ends
1. Remove the existing bar ends.
The inside of the bar should have a notched insert that matches the shape of the base of the bar end; our bar ends are made to fit a factory setup and will not work with a generic insert or any type of aftermarket race clip-on bars.
2. Apply a small amount of blue or red thread locker (Loctite) to the supplied screws.
3. Install the bar end making sure that the bar end notch is correctly mated to the bar insert and add light torque with a 5mm Allen wrench. If the bar end appears crooked it may indicate that the notch on the bar end and bar insert are not aligned correctly.
4. Confirm that the bar grip on the throttle side does not touch the bar end and that the bar end does not inhibit smooth throttle twisting action in any way.
Fork Sliders
Items/tools needed:
Torque wrench
22mm socket
Ratchet
5mm Allen wrench
Blue and red Loctite
Our fork sliders are designed to work with the factory axle assembly and do not replace the factory axle or modify the factory axle mounting position. However, the kit does replace the factory axle bolt with our special mounting bolt.
This set will only fit the 2005-2006 600RR which came standard with inverted forks.
1. Remove the factory axle bolt with your 22mm socket/ratchet. Do not loosen or remove any other bolts.
2. Install and tighten the axle bolt that is supplied with the fork sliders kit. Use a torque wrench set to the factory specified amount of torque.
3. Use red Loctite on the supplied screw for the left side fork slider and attach the slider to the aluminum rod in the kit. The left axle slider has an extended base that is designed to fit into the axle.
4. Add blue Loctite to the threads of the right side fork slider screw and insert through the axle slider. The right side axle slider is cupped in a way that covers the bolt head when installed correctly.
5. Insert the left side axle slider/rod assembly into the left side of the axle and hold firmly in place.
6. Add the right side axle slider by inserting the screw through the hole in the OES supplied axle bolt and tightening onto the connecting rod. Once started, the screw should thread into the rod easily.
7. Use light torque to tighten the screws- if the left side turns you can hold it with another wrench.
Warning! Do not over tighten- the threads in the connecting rod will strip if too much force is used. A new rod can be purchased if the threads are damaged.
Swingarm Spools
Add a small amount of blue thread locker (Loctite) to the supplied screws and tighten with a light amount of torque using a 6mm Allen wrench.
We will be more than happy to provide customer support if needed- please contact us.
