Because there is already an existing Vortex Rearset installation for the 07-08, I'll be reference it and add a few pointers to make this installation as painless as possible for the 05-06 600RR. I'm sure 03-04 is very much similar.
1. Read the instruction shown on Vortex Website to properly pre-installed your rearset. The main focus here is to attach the pegs onto the heel guard.
2. Go through the instruction written by michaelj
3. To be persistent. I'll start on the shifter side. Unscrew the original shifter and use the same screw for your new rearset. Although the rearset comes with two different length rods, a Vortex Rep recommended using the stock shifter to connect to the transmission and the short rod from Vortex connect from peg to swivel bracket. Some have used both without a problem, but I prefer to do it properly to avoid further trouble and the ease of adjusting the feel of each shift. It should look like so:
Using the OEM Screw, tighten the swivel bracket.
Since the stock rod took away the attention of the beautiful rearset, I spray painted so that it matches while it's off.
4. Now moving on to the brake side. If you haven't already bought the hydrolic brake light switch, go here:
Why do we need it? Because your brake light will not work with the new rearset. The stock rearset has 2 springs attached to your foot brake lever. One is to trigger the brake light, while the other pulled the foot lever back to normal position. Since your new rearset is designed differently, you'll need the Brake Light Switch to retain the functionality of your brake light.
Now onto the fun stuff, unscrew the bolt sitting onto of your hydrolic brake pressure and replace it with the brake light switch screw/bolt. There will be brake fluid leaking out, but not much. You don't need to bleed your rear brake. You can if you want to. I would install this first before taking the stock rearset apart, because one, you'll have leverage to unscrew the hydrolic brake system apart and two, the last thing that you'll want is brake fluid dripping down your new rearset. It will eat the paint.
5. Unclip the stock brake light activation wires and wire the new hydrolic brake light switch to it and tape it up with electrical tape. There's no polarity (positive or negative) between the two wires. Connect it either way and test your brake light. (Will it stand the heat? It all depends on how you hide the wires or wether you have the heat shield on.)
6. Install the heatshield bracket. I used the longer silver bracket, but use either one to make it fit. Install the heatshield to the rearset from the inside, using the screw that came with the set. The end of the screw will be facing you. Again, this set is made for both 600RR and 1000RR so the set included two brackets, you only have to use one.
The finishing look:
Good luck and enjoy the new look. :icon_supe