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ZX10R 2004-05 instructions 04/29/06
INSTALLATION INSTRUCTIONS FOR: ZX-10R 2004-05
1) This kit requires that you very slightly trim the rubber portion on the key (see photo). Most users make an extra
key on a smaller blank. Be sure you’re comfortable with this modification before you start.
2) It is mandatory to use Blue Loc-tite on all bolts. We promise they will come loose if you don’t.
3) Remove the 36mm nut and washer that holds your triple clamp on and replace it with the new 36mm hex style
“grooved nut” that we provide. Do not use the stock washer under our nut. Torque the new nut to the
factory manual setting, which is normally a minimum of 85-ft lbs.
4) Install the new “triple clamp damper mount” (TC mount) over the 36mm nut with the “machined register” (the
tab on the backside) over the back of the triple clamp. The tab insures the mount cannot spin should the
damping forces try to loosen the main nut. It should match the contour exactly.
5) Be sure this “TC mount” is setting down flush on the triple clamp surface. This part is machined precisely to fit
over the Scotts triple clamp nut. The groove machined into the nut is positioned so once the setscrews are
tightened, it will suck the damper mount down against your triple clamp.
6) Tip to save time: Before installation, using Loc-tite, start all the setscrews first, until flush with the inside bore.
7) Using blue loc-tite on the setscrews, get them started until even with the inside bore. Starting with the 2 &
10 o’clock positioned screws, seat those first so the tab on the back is pulled up against the triple clamp. Then
proceed to tighten each one equally, working your way around until they are all equally tight. They should be
checked after the first ride as they can settle into the groove in the nut & require tightening after the first ride.
8) (Note: You must use some heat to compromise the Loc-tite before trying to remove the setscrews or the small
Allen head setscrews can be stripped easily).
9) Remove the two, stock-front tank retaining bolts. You will replace these with longer ones in the kit. Be sure to
retain the stock washers as they will go between the rubber tank biscuits and the bottom of our frame bracket.
10) Install the frame bracket tower with the offset in the tower closest to the triple clamp as in the picture!
11) Install the longer Allen tank bolts provided and tighten from 6-8 ft lbs.
12) Grease the shaft portion of the tower pin and drop it in the tower-pin hole. It is designed to “float” and requires
no retaining devices. Keep the tower pin and hole portion greased so the tower pin can float!!
13) Install the stabilizer using the (2) 6x20 Allens, aligning the slot in the link arm to matching the tower pin. Check
to be sure the linkarm is not resting on, or touching the black nylon collar on the tower pin.
14) Read your damper manual for initial settings on the controls. The damper is infinitely adjustable and totally up
to the user to find their preference. Start with softer (counter clockwise) settings.
15) If you have any questions about anything, please call, we want to help you install this correctly.
Frame bracket CBR’sTriple clamp mount
Front
Trim the stock key similar to the dotted line or have a
spare key made that is a smaller blank to start with.