Rebuilding a ‘05 636 - Page 4 - ZX6R Forum
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post #46 of 77 Old 11-06-2018, 09:55 PM Thread Starter
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The magic of the electrolysis for cleaning rust out of a fuel tank
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post #47 of 77 Old 11-07-2018, 08:44 AM Thread Starter
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Took the ignition to a local locksmith...$25 and should be ready later on today
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post #48 of 77 Old 11-07-2018, 06:26 PM Thread Starter
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Night 2 of electrolysis
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post #49 of 77 Old 11-07-2018, 09:15 PM Thread Starter
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This pic is after tonight’s 3 hours of electrolysis...about 5 hours total. Big difference from how the tank was a couple of days ago. I’m shooting for 10-12 hours and then a nice steam clean before I do a POR15 treatment.
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post #50 of 77 Old 11-08-2018, 06:24 AM
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Is POR15 actually fuel proof or just fuel resistent?

P aint
O over
R ust
1
5

woohoo we are having fun now
Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
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post #51 of 77 Old 11-08-2018, 07:09 AM Thread Starter
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Quote:
Originally Posted by riverszzr View Post
Is POR15 actually fuel proof or just fuel resistent?

P aint
O over
R ust
1
5
The fuel tank formula is fuel proof and it works wonders! I’ve successfully used it before and it works best after removing as much rust as you can.
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post #52 of 77 Old 11-08-2018, 08:30 AM Thread Starter
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Just got a call from the keymaker. He’s going to need the tank to make the key
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post #53 of 77 Old 11-09-2018, 09:17 PM Thread Starter
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Any experts on the gas cap? After having two keys made, I was finally able to open the gas cap. I lubricated everything but the rubber seal on the cap is basically garbage. Can I replace that seal? All of the little springs giving the seal the tension it needs kept falling out so I bagged them and stored them until I find that seal. Advice is appreciated

# 92093-1030 Part number?

Should i order anything else?

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post #54 of 77 Old 11-09-2018, 11:59 PM Thread Starter
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Also, removed the seat for the first time and there are two wires that are electrical taped together. Don’t know if that is for the turn signals or what...no power commander which is weird because bike has muzzy exhaust and k&n filter
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post #55 of 77 Old 11-10-2018, 11:28 AM
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Quote:
Originally Posted by Spyvsspy View Post
Any experts on the gas cap? After having two keys made, I was finally able to open the gas cap. I lubricated everything but the rubber seal on the cap is basically garbage. Can I replace that seal? All of the little springs giving the seal the tension it needs kept falling out so I bagged them and stored them until I find that seal. Advice is appreciated

# 92093-1030 Part number?

Should i order anything else?
I do not see the zx6r included in the application list..............but it may well be the same

kawi application list of what this fits in 05

2005 KL250-D22 - Fuel Tank
2005 KL650-A19 - Fuel Tank(3/4)
2005 ELIMINATOR 125 (BN125-A8) - Fuel Tank(2/3)
2005 NINJA 250R (EX250-F19) - Fuel Tank(4/4)
2005 NINJA 500 (EX500-D12) - Fuel Tank(5/6)
2005 NINJA ZX-12R (ZX1200-B4) - Fuel Tank (B3/B4)
2005 VULCAN 1500 DRIFTER (VN1500-R5) - Fuel Tank(4/4)(R2∼R5)
2005 VULCAN 1600 CLASSIC (VN1600-A3) - Fuel Tank
2005 VULCAN 750 (VN750-A21) - Fuel Tank(3/3)
2005 VULCAN 800 (VN800-A11) - Fuel Tank(2/3)
2005 VULCAN 800 DRIFTER (VN800-E5) - Fuel Tank(3/3)
2005 Z1000 (ZR1000-A3) - Fuel Tank
2005 ZZR1200 (ZX1200-C4) - Fuel Tank
2005 ZZR600 (ZX600-E13) - Fuel Tank(4/4

woohoo we are having fun now
Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
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post #56 of 77 Old 11-10-2018, 06:55 PM Thread Starter
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It wasn’t included since that part is listed as a California only part apparently. Ordered one up and should have it in a few days. On a side note, there isn’t alot of info on these bikes online like there was when I rebuilt a CBRF4i. Also, zx6r.com isn’t very active either. Anybody know of a good forum where I might get more interaction when I have ??’s
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post #57 of 77 Old 11-11-2018, 08:02 AM
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Quote:
Originally Posted by Spyvsspy View Post
It wasnít included since that part is listed as a California only part apparently. Ordered one up and should have it in a few days. On a side note, there isnít alot of info on these bikes online like there was when I rebuilt a CBRF4i. Also, zx6r.com isnít very active either. Anybody know of a good forum where I might get more interaction when I have ??ís
lol....

active with a bunch of bullshit stupid answers................go to the facebook page or any other kawi forum

You want the right answer, well there are scant few people who know the right answers.......... whom are also willing to give that information out for free....

The world is not instant gratification at your whim- people have real jobs and real lives..........sorry to dissapoint you but us smart people with the answers are not on call 24/7 to any forum
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woohoo we are having fun now
Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
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post #58 of 77 Old 11-11-2018, 08:03 AM
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Quote:
Originally Posted by Spyvsspy View Post
Also, removed the seat for the first time and there are two wires that are electrical taped together. Donít know if that is for the turn signals or what...no power commander which is weird because bike has muzzy exhaust and k&n filter
What is the color code and did you follow the electrical schematic to see what they are?

woohoo we are having fun now
Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
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post #59 of 77 Old 11-11-2018, 08:06 AM
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Quote:
Originally Posted by Spyvsspy View Post
Any experts on the gas cap? After having two keys made, I was finally able to open the gas cap. I lubricated everything but the rubber seal on the cap is basically garbage. Can I replace that seal? All of the little springs giving the seal the tension it needs kept falling out so I bagged them and stored them until I find that seal. Advice is appreciated

# 92093-1030 Part number?

Should i order anything else?

Those springs should not fall out

the cap assembly;
well when you close the caap- it pushes up and locks in place- if you have it oopen you can cycle it by hand........

I have no doubt all that rust and corrosion in the tank has affected the cap mechanism as well and you likley are far better off to just replace the cap with a new one...........oe or aftermarket is up to you
oe you could swap your lock mechanism over to still be keyed to match the ignition

woohoo we are having fun now
Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
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post #60 of 77 Old 11-11-2018, 12:52 PM Thread Starter
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I think the gasket has something to do with keeping them in place. They stayed in until I noticed I ripped the bottom part of the gasket out.

I cleaned out the airbox, K&N filter, secondary injectors, primary injectors, and have to figure a way of repairing the chewed wire. Trying to get this thing ready to fire once the fuel tank is ready
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