Kris' Corner Part 2 -- Installing Vortex rearsets

[kr1s]

I created a Word document as I was going to load the template onto my website and I forgot I have it down because I am rebuilding it. So, there are no photos with this because they are embedded in the Word document. (There are 16 photos) E-mail me if you want the 2MB Word doc.

Vortex RS415 How-To

Introduction
It’s not often that I write about a product without getting something out of it, but I have used Vortex rearsets and levers on my 08 CBR600RR and now on my 09 ZX-6R. When something is just “that good”, you tend to stick to it. Since Kawi introduced the 09 ZX-6R and floored the masses as the “Best 600cc bike of 2009”, manufacturers have been hammering away to get some goodies in the hands of consumers.

My first mod were the levers. A straightforward 1-2 bolt remove and replace is all it took so I won’t bore you with the how-to. The rearsets however, like the 09 ZX-6R come with some trick parts and should be noteworthy to write about.

Upon visual inspection of the rearsets, the same lightweight sturdiness of Vortex is present when the box is opened. There are subtle differences though. On previous versions of Vortex’s rearsets, the shift and clutch levers were incorporated into the peg. This time, they have their own mount location. As well, the toe levers fold in, and there are some nice little puck/sliders on the ends of the foot pegs should you take a spill. As a side note, you color aficionados need to find your favorite powder coater because for 2009, Vortex rearsets only come in black.

Tools needed
3/8” drive ratchet
14mm 12 point 3/8” drive socket
4 or 6” 3/8” drive extension
4mm allen 3/8” drive socket
6mm allen 3/8” drive socket
10mm combo or open end wrench
Pliers
Red loctite
DOT 4 brake fluid
2 3/8” hose clamps*

*Note: I will shoot an e-mail to Vortex suggesting incorporation of those clamps…Maybe it will work!

I started off on the right side since it was easier to get to in the garage and the most labor intensive. The stock rearset is nice, but for added grip, adjustability, and cornering, the Vortex rearsets are the way to go.

In my case, I have an M4 GP style exhaust so it was easier to take off the heel plate first with a 6mm allen.

Hitting up the rearset mount with a 6mm allen got the rearset dangling.

You then have to disconnect the brake light switch. It should be replaced with Vortex’s switch which is P/N RS100. I did not do this right now so I simply pushed in the two tabs to release the switch from the mount, and took off the return spring. In the area where the brake fluid reservoir is, you can see the plug that it plugs into. Unplug this.

At this time, it is best to remove the hose from the reservoir to the master cylinder and place it aside. Make sure that you do not allow brake fluid to contact paint as it will damage it. Vortex’s kit supplies another hose for extension. A 4mm allen will remove the reservoir cover so that you can take the reservoir out.

Next up was mounting the rearset mount to the frame. Using your factory bolts, install the block against the two mounting holes with a 6mm allen..They should only install one way.

The brake lever has a few pieces to it. Included in the kit is a toe peg and some hardware. Vortex’s instructions give a good illustration of how the spring and toe peg align and mount up. A base plate is included that acts as the hinge mount and this is secured with a small allen adding some red loctite. A little lube should be applied to the pin as you insert it in and then retained by a snap ring. My snap ring pliers are too big for this ring, so I simply used two picks to open the ring.

The back of the brake lever is drilled for the master cylinder plunger. After removing the cotter pin from the stock rearset, place it into the Vortex lever and bend the ends of the pin.

Now would be a good time to attach the hose to the master cylinder and secure it with a hose clamp. Also, you will use the stock bolts to secure the master cylinder to the heel plate of the rear set.

Pegs are mounted from the reverse side of the heel plate. Align the notches and secure with the supplied 6mm button head allen bolt.

As well, lube the pivot bolt and slide through the lever using the supplied washer on the backside and mount it to the heel plate.

Now, depending on your exhaust, the adjustability may be limited. Since I preemptively purchased the M4 exhaust, my options were limited. Stock mounting would be bolting the rearset to the mount at the front bottom hole. Due to my exhaust, I am unable to leave it in the stock position, so I chose to simply raise the height of my rearsets. In this case, I chose the top forward hole. NOTE: NON-GP STYLE EXHAUSTS WILL MAINTAIN YOUR ADJUSTABILITY OF THE REARSETS.

As mentioned earlier, Vortex includes some sliders/pucks for the end of the pegs which look like little mushrooms. I hammered those in with a rubber mallet.

The right side is complete.

At this point, you will want to push the Vortex supplied hose on the reservoir securing it with a hose clamp. You should then bleed your rear brake to ensure all of the air is out. This is where the DOT 4 fluid comes into play.

The left side is much more straight-forward and less time consuming. With the 10mm open end wrench, I loosened the shift linkage.

A 6mm allen is used to remove the entire rearset.

The linkage mount on the transmission is obviously in the stock position. This provides standard shifting. Should you want a GP style patter, simply with a 10mm socket, remove the bolt and place the linkage mount so that the bottom is now on the top.

For the left side, I simply assembled the entire rearset as a whole with the lever, the toe peg, the foot peg, the heel plate all to the mount as mentioned in the right side installation. This leaves only the 6mm stock bolts to be reinstalled on the mount. Again, to maintain symmetry, I installed the left side in the same position as the right side.

In the position I chose, I used the shorter of the two linkages supplied with the kit. It is a matter of preference of where you want the position and I rode the bike a little to make adjustments.

Now you’re done.

Impressions

I have always loved the craftsmanship of the Vortex products. The rearsets on my CBR gave me more confidence that my feet would stay in place and that I could lean just that little bit further. As for the Kawi, these are a great improvement after just a simple ride around the neighborhood to make sure that they are solid. Definitely a good bang for the buck.

[HondaHugger]

Kris, can you email the doc to me and I'll upload the pics for you?

[HANS]

pics would make this 1000x better. its just hard to grasp the specifics without pics.

i mean at least for me i know exactly everything you explained but for others it can get confusing.

good write up though.

[kr1s]

Yeah....HH is trying to upload the pics...I have the word doc here and doing work on my website so it sucks....But I will get them up..

And thanks!!!!


Kris

[LOZ]