Rear aftermarket shock overhaul on a 2006 AE

[yamafitter]

Many years ago I replaced the rear shock on my FJR AE with a Wilbers with remote reservoir and hydraulic preload adjuster. I had it serviced once by GP Suspensions and then once again when I had the rear end apart doing linkage service. It would be a fairly simple task to pull the shock itself except that the mounting of the reservoir is such that it requires that the AE Master Clutch mechanism needs to be moved to make room for the reservoir to be removed without disconnecting the hydraulic line connecting the reservoir to the shock body.

To access the master clutch assembly is not that simple since a lot of the ABS plumbing is in the way and I wanted to check the swingarm bearings so I ended up pulling the swingarm which required pulling the driveshaft and a number of other bits and pieces along the way. I will probably also take the opportunity to rebuild the master clutch assembly while I have everything apart.

I took the Wilbers shock over to an authorized Wilbers service center in the area (Buckhorn) but unfortunately they are severely backed up and it is going to be 6 to 8 weeks before I get the shock back. I also ordered the parts required to service the forks so I will be doing that while I wait but that is only a one day job anyways.

This might just be the final impudence I needed to go out and get that 700 Tenere. Just hoping I remember how everything goes back together.

[raYzerman]

You know if you make me come over there..... be aware I have never worked on an AE nor did I witness the 'deconstruction', therefore all I can offer you is that your beer and whiskey supplies will be taken down a notch. Then I will be more likely to forget stuff and my blurred vision may not be able to interpret the FSM correctly. All you have to do is decide if you want my 'help'.

[Abercrombie FJR]

You know if you make me come over there..... be aware I have never worked on an AE nor did I witness the 'deconstruction', therefore all I can offer you is that your beer and whiskey supplies will be taken down a notch. Then I will be more likely to forget stuff and my blurred vision may not be able to interpret the FSM correctly. All you have to do is decide if you want my 'help'.

Ya can't resist an offer like that!

[gixxerjasen]

I've said it before and I'll say it again.

Yamaha Service Manual:
Shock removal
1. Remove top bolt.
2. Remove bottom bolt.
3. Remove shock.

FJR AE Owner:
F*CK YOU YAMAHA!!!!

[yamafitter]

I've said it before and I'll say it again.

Yamaha Service Manual:
Shock removal
1. Remove top bolt.
2. Remove bottom bolt.
3. Remove shock.

FJR AE Owner:
F*CK YOU YAMAHA!!!!

The FSM was written by someone that is not aware of the existence of the AE model.

[yamafitter]

You know if you make me come over there..... be aware I have never worked on an AE nor did I witness the 'deconstruction', therefore all I can offer you is that your beer and whiskey supplies will be taken down a notch. Then I will be more likely to forget stuff and my blurred vision may not be able to interpret the FSM correctly. All you have to do is decide if you want my 'help'.

Not only will Ray completely deplete my stock of 40 Creek he will be spending far too much time routing through my toolbox. The only reason he won’t be leaving with a truckload of my tools is that he doesn’t own a truck anymore. He now has a Jeep. Yes, he is one of THOSE people.

Actually I was the one that ended up with FYB’s screwdriver but Ray got blamed for it. I’m good with that

[ionbeam]

I've said it before and I'll say it again.

Yamaha Service Manual:
Shock removal
1. Remove top bolt.
2. Remove bottom bolt.
3. Remove shock.

FJR AE Owner:
F*CK YOU YAMAHA!!!!

The FSM was written by someone that is not aware of the existence of the AE model.

2007 and up shows a separate AE service manual, does it not show AE parts in the rear shock service section?

[yamafitter]

While the comment was somewhat facetious it is not as simple as removing the rear and top shock bolts. The larger issue with my aftermarket shock however is the routing required to mount the remote reservoir. There is simply no way of getting the shock out with the remote reservoir intact without unbolting the AE master clutch cylinder mechanism. The easiest way to perform that is to remove the swingarm.

I would have preferred a piggyback Ohlins but unfortunately it will not fit due to the restricted area at the top of the shock. You are required to use the remote reservoir shock. The hydraulic preload adjuster mounting is straightforward and very simple but the reservoir, not so much.

Unfortunately I don't have any photos to show the issue caused by the need to remove all the bits and pieces. It is going to be awhile before I have the shock back and then I will be able to take a few photos that will show the problem more clearly, a picture being worth a thousand words.

[gixxerjasen]

Which aftermarket shock do you have? I don't recall any issues with that specifically. It's been a while since I've been through this beer drinking intense cussing operation. I remember something about the top bolt being easy to loosen but impossible to remove because something was in the way. I don't remember the specifics though, but I'll likely be doing this again in the near future.

[yamafitter]

The issue with the top bolt is that you can get the bolt out that the bracket that holds the ABS block is in the way. If you move the shock and turn the bolt head just right you can get the bolt out and remove the shock.

I have a Wilbers shock the reservoir gets mounted just beside the rear brake pedal. The hose runs between the frame and clutch master cylinder assembly. It is impossible to remove the shock and reservoir without removing the clutch assembly.

[gixxerjasen]

The issue with the top bolt is that you can get the bolt out that the bracket that holds the ABS block is in the way. If you move the shock and turn the bolt head just right you can get the bolt out and remove the shock.

THAT is it. Now I remember. Sucks about that issue with the reservoir, don't recall that with the Penske I don't think.

[HotRodZilla]

The issue with the top bolt is that you can get the bolt out that the bracket that holds the ABS block is in the way. If you move the shock and turn the bolt head just right you can get the bolt out and remove the shock.

I have a Wilbers shock the reservoir gets mounted just beside the rear brake pedal. The hose runs between the frame and clutch master cylinder assembly. It is impossible to remove the shock and reservoir without removing the clutch assembly.

Would any of that change if you relocated the shock reservoir? My reservoir with the adjustment knob is just a hair forward of, but behind my right bag near the top of the bag. I don't have an AE and I've never looked under one's skirt, so I have no idea how cluttered it is under there. Just a thought though!

[raYzerman]

It doesn't matter which shock, getting past that ABS plumbing is tight.
You can mount the reservoir various places, but you want it high enough and clear of swingarm travel.........

[yamafitter]

Here is a photo of the bracket that holds the reservoir that Wilbers supplied and how little space there is to route the hose between the clutch master cylinder and the frame above the swingarm. In this photo the swingarm is already removed. Because of all the other plumbing with ABS and all the other lines associated with the AE there really is not a tidier location for the reservoir. Since I only need to service the shock every two years based on the limited mileage the FJR has gone over the last few years it is not that bad since taking the rear end all apart gives me the opportunity to service all of the other suspension linkage at the same time....

[Road Runner]

Oh boy. I just saw this tread. I am going to be installing an Ohlins YA-707 with a remote reservoir on my 08 AE soon. The Ohlins reservoir gets mounted where the rear set and muffler hanger is bolted to frame. I hope that is easier, fingers crossed.

[Road Runner]

Many years ago I replaced the rear shock on my FJR AE with a Wilbers with remote reservoir and hydraulic preload adjuster. I had it serviced once by GP Suspensions and then once again when I had the rear end apart doing linkage service. It would be a fairly simple task to pull the shock itself except that the mounting of the reservoir is such that it requires that the AE Master Clutch mechanism needs to be moved to make room for the reservoir to be removed without disconnecting the hydraulic line connecting the reservoir to the shock body.

To access the master clutch assembly is not that simple since a lot of the ABS plumbing is in the way and I wanted to check the swingarm bearings so I ended up pulling the swingarm which required pulling the driveshaft and a number of other bits and pieces along the way. I will probably also take the opportunity to rebuild the master clutch assembly while I have everything apart.

I took the Wilbers shock over to an authorized Wilbers service center in the area (Buckhorn) but unfortunately they are severely backed up and it is going to be 6 to 8 weeks before I get the shock back. I also ordered the parts required to service the forks so I will be doing that while I wait but that is only a one day job anyways.

This might just be the final impudence I needed to go out and get that 700 Tenere. Just hoping I remember how everything goes back together.

Oh boy. I just saw this tread. I am going to be installing an Ohlins YA-707 with a remote reservoir on my 08 AE soon. The Ohlins reservoir gets mounted where the rear set and muffler hanger is bolted to frame. I hope that is easier, fingers crossed.