The chronicles of Otto Man's racing adventures - ZX6R Forum
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post #1 of 11 Old 03-28-2019, 08:34 AM Thread Starter
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Join Date: Mar 2012
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I Ride: '12 ZX6
The chronicles of Otto Man's racing adventures

I decided to start this as I have been learning a ton about the ZX6 over the last few years. I figured putting some of the knowledge and lessons learned on here might save some headache in the future for others. My first track bike was a '05 636. Like any good newbie, I crashed the shit out of it. It was a tank and held up great. I sold it after my first track season and bought a R6. Had the R6 for a few years, took my first ambulance ride with it, won my first Expert races, generally, did a shit ton of riding on it. I also bought a '05 ZX10 (always loved them) and coached/raced it a bit in the V8 Heavy weight class with WERA. Won my first national championship with it in 2017. A few years ago, I became good friends with Randy. He always seemed to have Kawi's for some reason, and because of him, I've found myself naturally gravitating back to Team Green. More on him, the endurance racing, and all that can be found on this thread:

https://www.zx6r.com/racing/97113-20...nce-build.html

So after I got the endurance bike, I sold the R6 because I didn't see the point in having 2 different 600's and my ZX10. I sold my 10r, and picked up a '07 ZX6 to race, so I could continue to race in the V8 class (both medium weight and heavy weight) this year. Additionally, there is far more in common parts-wise with the '07 and the '09 than the '09 and '05 ZX10. I also pick up project bikes over the winter and do what I can to help supplement my trackday/racing budget, so I always have shit and projects in the garage.

Random pic of me rippin' on the endurance bike back in 2016, cause everybody loves wheelies.
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'12 ZX6 - 3 Marines Racing Endurance Team Bike
'07 ZX6
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post #2 of 11 Old 03-28-2019, 08:40 AM
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I Ride: '09 ZX6R
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2007 ZZR600 (sold)
2006 CBR600 (sold)
2010 1198 (parted out across North America)
2013 CBR500R (sold)
2009 ZX6R (parted out across North America)
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April 2016 and April 2017 6OTM winner!
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post #3 of 11 Old 03-28-2019, 09:00 AM
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Awesome! More please
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post #4 of 11 Old 03-28-2019, 09:02 AM
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Tactically following...this gonna be on netflix?
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2013 ZX-6R
Hindle Exhaust(Can), SHOGUN FS, ASV shorty levers, Renthal C/O, BMC Airfilter,
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post #5 of 11 Old 03-28-2019, 09:24 AM Thread Starter
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I Ride: '12 ZX6
Next up: Project bike. 2007. Picked this up for a good price, but had a hole in the motor, right above where the clutch is. Tim (Backmarker on here) was over at the house and guessed the clutch exploded. As soon as I popped the clutch cover off, I knew he won the prize. The basket literally exploded. I have no idea how. All I know is that there were pieces everywhere, no part of the basket to be found in one piece, and the crank had managed to suck up pieces of the discs/basket/ into #4 and somewhere along the way, shit got in between the piston and valves, and the intake valves got bent to shit. All I know is that this thing had to make one HELL of a racket when it exploded.

I just happened to have an extra '09 motor laying in my garage (I told you I have a lot of shit), and from my googling on here, it seemed I could just swap motors, because it's the same motor. Swap motor out, sell it, easy day.

It IS the same motor, but it's not. Yes, it will physically bolt into the frame, but there are several key, very important differences:

The 07-08 wiring harness uses a camshaft position sensor. The 09-12 does not. The 09 head has the casting built in where that sensor would bolt to, but it's not physically drilled or tapped for it. Well, so much for just a motor swap...

Stator plug is different, tip over sensor plug is different. Throttle bodies, while using the same electrical connectors, are different as well. The 09-12 TB's are about a 1/4" taller. This made my choice for me...swap over the harness to the 09-12. Not that big of a deal...since I had an extra harness

The upper engine mounting cast on the 09 is skinnier than the 07. I just so happened to have this random aluminum spacer (I never throw away usable nuts/bolts/spacers) that worked perfectly. You can see the brushed aluminum spacer being put to work. Where did it come from...no idea. All I know is that it worked perfectly and it was literally the exact size I needed. I suppose you could always make a sleeve or stack a shit ton of washers if you wanted to.

The '07-08 air box DOES fit on the 09-12 throttle bodies, which is good...because the 09 air box won't fit as the frame is too skinny on the 07. That is where I'm currently at - pulling out the '07 harness and putting in the 09. This gives me a spare harness for my personal '07...not a bad thing. Long term, I plan to completely strip that harness and make it race only and swap it over to mine. that will clean up the wiring on it and not make my eye twitch every time I take off my race bodywork.

Thankfully the transmission in the blown up engine appears to be good. Another track side spare.
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WERA Expert #37
N2 Track Days Control Rider
'12 ZX6 - 3 Marines Racing Endurance Team Bike
'07 ZX6
Sportbike Track Gear
Woodcraft
Andrew Swenson Design
N2 Track Days
It is always those that use their brakes the least that want to upgrade them the most.
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post #6 of 11 Old 03-28-2019, 09:51 AM Thread Starter
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Picked up this bad boy a few weeks ago...this is where all the stuff going into my project bike came from. Another 09-12. Friend of mine crashed his bike and fucked it up something good, and sold out of the sport. Crushed the headers, broken the frame in multiple places - total loss. Motor runs (or did up until he wrecked it). Typical track day build on it, so a ton of great spares (and extra wheels...I love extra complete sets of wheels LOL). The forks have 25mil Ohlins carts in them, but the sanctions are definitely bent. I will have Thermosman see if the carts survived the impact...if so, I'll get some stock, non crashed forks and have some nice forks for the future.

Stripped her down, labeled all the parts, increased my bolt supply 3 fold, and got some sick pleasure from sawzall'ing a frame into multiple pieces so it would fit in the recycling bin easier.
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WERA Expert #37
N2 Track Days Control Rider
'12 ZX6 - 3 Marines Racing Endurance Team Bike
'07 ZX6
Sportbike Track Gear
Woodcraft
Andrew Swenson Design
N2 Track Days
It is always those that use their brakes the least that want to upgrade them the most.
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post #7 of 11 Old 03-28-2019, 10:05 AM
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Damn...such a bummer to see people sell out of the sport completely when that happens. Your spare parts supply is getting intense. I know who to contact if I need something now lol
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post #8 of 11 Old 03-28-2019, 11:42 AM Thread Starter
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Tim has me beat ten fold when it comes to spares...between him and I, we could probably have a Kawi yard sale stand in the paddock each weekend... lol
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WERA Expert #37
N2 Track Days Control Rider
'12 ZX6 - 3 Marines Racing Endurance Team Bike
'07 ZX6
Sportbike Track Gear
Woodcraft
Andrew Swenson Design
N2 Track Days
It is always those that use their brakes the least that want to upgrade them the most.
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post #9 of 11 Old 03-28-2019, 05:22 PM
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When do we get the lightened frame holes
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post #10 of 11 Old 03-28-2019, 08:33 PM Thread Starter
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Quote:
Originally Posted by Gawernator View Post
When do we get the lightened frame holes
Sorry...that's an east coast specialty.

Got the project bike running tonight. I was pissed when it fired up for about a second, then shut off. I then realized I totally forgot to plug in the tip over sensor. Fired right up after that.

Was kind of worried when the low oil light wouldn't go out after 10 seconds or so...then I realized it wasn't the oil lamp flashing, it was the F1 light. Gotta pull the codes to see what it is.

Going to be an absolute joy to tuck all this 09 wiring into this 07 frame and subframe...
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WERA Expert #37
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'12 ZX6 - 3 Marines Racing Endurance Team Bike
'07 ZX6
Sportbike Track Gear
Woodcraft
Andrew Swenson Design
N2 Track Days
It is always those that use their brakes the least that want to upgrade them the most.
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post #11 of 11 Old 04-03-2019, 06:04 AM Thread Starter
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I Ride: '12 ZX6
Was getting a code 39, no communication between the cluster and ECU error on the bike. After doing a bit of digging on the wiring harness, I found these 2 butt connectors and scotchlok connector. Two of them had broken wires. I cut these stupid ass things off, and soldered them with some heat shrink tubing. Problem solved.

These things should be banned for use for any application, and they are a personal pet peeve of mine...for reasons exactly like this.

The bike is now FI code free and runs awesome. Time to piece it back together and get her sold to clear up some much needed garage space!
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N2 Track Days Control Rider
'12 ZX6 - 3 Marines Racing Endurance Team Bike
'07 ZX6
Sportbike Track Gear
Woodcraft
Andrew Swenson Design
N2 Track Days
It is always those that use their brakes the least that want to upgrade them the most.
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