Rebuilding a ‘05 636 - ZX6R Forum
 10Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 72 Old 10-20-2018, 11:45 PM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
Rebuilding a ‘05 636

I just purchased a 636 that has been kept in a shed since 2009. I look forward to starting a build thread and sharing the process with everybody here. Also look forward to any knowledge from other forum members throughout the process!

This will be my 2nd Kawasaki and my 2nd attempt at bringing back some life to an abandoned motorcycle. My first attempt was very successful and only took 2 weeks from start to finish when I found a neglected 2001 CBR F4i.

I already received the title and am waiting to pick up the 636 next week! Cheers to all!
Spyvsspy is offline  
Sponsored Links
Advertisement
 
post #2 of 72 Old 10-21-2018, 02:26 AM
Post Master General
 
RJ2112's Avatar
 
Join Date: Apr 2012
Location: Bowling Green, VA
Posts: 11,449

I Ride: '09 ZX6R
'05 are known for issues with the ECU..... The under seat exhausts tend to cook them in some cases.

Other than that, seems like a stellar bike.

"Basic stuff fellas. Use your head for something other than to break your next fall."
RJ2112 is offline  
post #3 of 72 Old 10-21-2018, 07:21 AM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
Quote:
Originally Posted by RJ2112 View Post
'05 are known for issues with the ECU..... The under seat exhausts tend to cook them in some cases.

Other than that, seems like a stellar bike.
Thank you, RJ. This is the type of insight that I’m looking for. The bike does have an undertail Muzzy exhaust...was the stock exhaust the culprit or any undertail exhaust?
Spyvsspy is offline  
Sponsored Links
Advertisement
 
post #4 of 72 Old 10-21-2018, 11:03 AM
Post Master General
 
RJ2112's Avatar
 
Join Date: Apr 2012
Location: Bowling Green, VA
Posts: 11,449

I Ride: '09 ZX6R
No direct experience, so it's all anecdotal.... if I had to guess, I'd think any aftermarket can would not be as insulated as the OEM can. Hence, more heat under the seat. Airflow is a crucial part of the cooling process -- if someone adds an aftermarket module under the seat area, and that blocks airflow (which is already substandard IMHO) and adds some amount of heat as well -- when you cap that off with the heat from the catalytic converter burning off the excess fuel, into a less insulated muffler system I can see how it may end up hot enough to start breaking down the ECU. The cat would burn off more, if a fuel enricher is in use, as more would make it out of the cylinder and onto the cat.

The typcial solution is to replace the '05 ECU with one from an '06. As I have no idea if there is any physical difference between the model year ECUs, I have to wonder how successful this approach is. You don't hear anywhere near as much about '06 having this issue, so there's some real possibility of a change.

Were I to buy an '05 in need of TLC, I'd probably start with gutting the catalytic converter. That's going to reduce the exhaust temp by quite a lot of degrees. It will stink more, and may appear more sooty at the tip of the muffler; if it's cooler exhaust that can only be good for the ECU. Next, I'd add some heat insulating tape on the side of the tray facing the pipe, to reflect away as much of the heat coming up off the pipe as possible. Make that patch wide enough to let the heat find another path up, that does not include penetrating the tail section.

If the '05 OEM ECU acts up after all of that, I'd get a used '06 ECU, if one can be found.

"Basic stuff fellas. Use your head for something other than to break your next fall."
RJ2112 is offline  
post #5 of 72 Old 10-21-2018, 03:29 PM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
I’ll keep all of that in mind. Hopefully this bike will just need a fuel system cleaning new tires and chain and a battery. All fluids of course
Spyvsspy is offline  
post #6 of 72 Old 10-21-2018, 03:59 PM
ZX6r.com Supporting Member
Supporting Member
 
Indy's Avatar
 
Join Date: Jul 2015
Location: Indianapolis, In
Posts: 2,919
Garage
Welcome to the forum.

Don't forget about the suspension fluids.
No issues with my 06 and under tail exhaust.
Indy is offline  
post #7 of 72 Old 10-21-2018, 07:05 PM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
Quote:
Originally Posted by Indy View Post
Welcome to the forum.

Don't forget about the suspension fluids.
No issues with my 06 and under tail exhaust.
Thanks! I may try to flip the 636...depends on how much I spend to get it up and running properly. If I keep it I will take it to a local suspension guy that used to race professionally
Spyvsspy is offline  
post #8 of 72 Old 10-24-2018, 08:35 PM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
A few photos of the bike. It has been stored in this shed since 2009. Looks bad but I’m excited. Has an oval Muzzy exhaust. I haven’t picked it up yet. Waiting for the keys.
Attached Thumbnails
Click image for larger version

Name:	EA64E0EB-9DA5-469E-8DD0-B597CB481FDB_1540438292033.jpeg
Views:	47
Size:	954.6 KB
ID:	90906  

Click image for larger version

Name:	DB90F435-B87B-46B4-8727-875B73480F2A_1540438347918.jpeg
Views:	44
Size:	929.5 KB
ID:	90908  

Click image for larger version

Name:	741FE7EC-64CC-4956-BD4E-80409CFAD638_1540438365987.jpeg
Views:	43
Size:	637.5 KB
ID:	90910  

Click image for larger version

Name:	62EB388C-61F4-42DB-826A-6C078CE0C009_1540438391902.jpeg
Views:	45
Size:	1.42 MB
ID:	90912  

Click image for larger version

Name:	89D7174C-8D7D-4D19-976C-E9A2CB749E93_1540438408875.jpeg
Views:	42
Size:	637.5 KB
ID:	90914  

Spyvsspy is offline  
post #9 of 72 Old 10-25-2018, 01:39 AM
Post Master General
 
RJ2112's Avatar
 
Join Date: Apr 2012
Location: Bowling Green, VA
Posts: 11,449

I Ride: '09 ZX6R
I'd expect suspension problems due to failed seals. Electrical connections will be suspect, and there is a significant chance of vermin having my moved in. Open the air box, check for rodent nests.

Tires, battery, brake lines, driveline. Valve clearance check....... Then, cosmetics.

"Basic stuff fellas. Use your head for something other than to break your next fall."
RJ2112 is offline  
post #10 of 72 Old 10-25-2018, 06:43 AM
Post Master General
 
PowerGroove's Avatar
 
Join Date: May 2011
Location: Somewhere in Central California
Posts: 11,619

I Ride: 09 ZX6R, 12 ZX6R, 2000 ZX6R, 99 Honda Shadow 1100, 81 Honda CB900C, 04 GSXR 600
Garage
Personally....

Full tear down to the frame. Maybe even drop the engine just to clean everything up.

It's dirty enough that it could use it.

Agreed with RJ

- That shed definitely has rodents in it. Airbox almost certaily has some shit (no pun) in it). Check for chewed up wires too.
- Suspension seals as mentioned.
- Toss the battery and get a brand new one.
- change ALL the fluids obviously (brake fluids too)
- Gonna need to fresh rubber too.

Assuming it's in working order it shouldn't be much to get refreshed. Nice find!

“Why do I ride as number 69? Well, it’s a number that you can still read when the bike is upside down after a crash." - Nicky Hayden

Quote:
Originally Posted by RJ2112 View Post
These fine gentleman are expressing their frustration with your learning style.
YouTube: Youtube.com/MotoMedic | IG: @1MotoMedic | @powergroove75
PowerGroove is offline  
post #11 of 72 Old 10-25-2018, 07:09 AM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
Thank you for the replies! I tried joining a few facebook 636 forums but the mods haven’t accepted me yet. Mainly trying to find part outs to pick up spare parts...going the budget route and need all the help I can get
Spyvsspy is offline  
post #12 of 72 Old 10-25-2018, 07:55 AM
Post Master General
 
PowerGroove's Avatar
 
Join Date: May 2011
Location: Somewhere in Central California
Posts: 11,619

I Ride: 09 ZX6R, 12 ZX6R, 2000 ZX6R, 99 Honda Shadow 1100, 81 Honda CB900C, 04 GSXR 600
Garage
Quote:
Originally Posted by Spyvsspy View Post
Thank you for the replies! I tried joining a few facebook 636 forums but the mods haven’t accepted me yet. Mainly trying to find part outs to pick up spare parts...going the budget route and need all the help I can get
I wouldn't bother with most groups on FB unless you're just looking for trolls.

Join this group for parts. https://www.facebook.com/groups/450439275077412/

“Why do I ride as number 69? Well, it’s a number that you can still read when the bike is upside down after a crash." - Nicky Hayden

Quote:
Originally Posted by RJ2112 View Post
These fine gentleman are expressing their frustration with your learning style.
YouTube: Youtube.com/MotoMedic | IG: @1MotoMedic | @powergroove75
PowerGroove is offline  
post #13 of 72 Old 10-25-2018, 04:36 PM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
That’s the group that I joined! Got accepted today
PowerGroove likes this.
Spyvsspy is offline  
post #14 of 72 Old 10-26-2018, 12:49 PM
Squid
 
Join Date: Aug 2018
Posts: 8
Quote:
Originally Posted by RJ2112 View Post
I'd expect suspension problems due to failed seals. Electrical connections will be suspect, and there is a significant chance of vermin having my moved in. Open the air box, check for rodent nests.

Tires, battery, brake lines, driveline. Valve clearance check....... Then, cosmetics.
My bike sat in the previous owners garage for 5 years. Clutch plates actually stuck together. I pulled more dry dog food out of the nooks and crannies of the bike than I care to remember due to mice....

good luck and keep us posted!!

Ducman
Ducman is offline  
post #15 of 72 Old 10-26-2018, 10:31 PM Thread Starter
Squid
 
Spyvsspy's Avatar
 
Join Date: Oct 2018
Posts: 48
Quote:
Originally Posted by Ducman View Post

My bike sat in the previous owners garage for 5 years. Clutch plates actually stuck together. I pulled more dry dog food out of the nooks and crannies of the bike than I care to remember due to mice....

good luck and keep us posted!!

Ducman
Did you reuse the clutch plates?

I was able to source a rightside rearset with brake reservoir and master cylinder. Still looking for a fuel pump and if I can’t find fuel injectors, I will just get mine ultrasonically cleaned.
Spyvsspy is offline  
Reply

  ZX6R Forum > Lobby > New Member Introductions

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
OG 636 models vs 2011+ 636 silthanas The ZX6R 6 08-22-2018 02:45 AM
2009 ZX6R to 636 Swap ZeeEx6Are New Member Introductions 0 06-16-2018 08:44 PM
Bloody Knuckles and Broken Nails: The Art of Rebuilding MistressOfMayhem The Build Thread 67 03-09-2015 12:09 AM
05 636 race plastics on 03 636 motostunter The ZX6R 2 07-12-2009 11:10 AM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome