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Discussion Starter #1 (Edited)
So I started out about a month or so ago with a 03 ZX-6RR frame with the intention of building a track bike. I had bought the frame (no title), sub-frame, 05 swing arm and wheel, 05 forks, triples, and gas tank. I had planned to use my 08 ZX-10R front wheel and brake rotors, as well as vortex clip ons, Brembo RCS, and kevlar lines. Well, while searching for an engine for it I ran across an 03 636 with under 10k miles that was missing all the plastics and the gas tank was pretty beat up. Needless to say it needed a lot of work, but it had a salvage title and it was barely more than just a motor would have been for the other frame and also included EVERYTHING needed to run. So, I picked it up and changed the plan a little. Now I have a bunch of 03/04 parts for sale and the bike is being built up. So for now she is really ugly, but I will work on that after I get everything squared away mechanically. Mainly I just want to get it ready for the track season next year and ride it as is for a while. As she sits now, here is the parts list of what I have and what I need/on the way.

Have:
2003 636
05 forks (stock for now, will get AK-20's after I sell my zx-10 AK-20's)
07 R6 monoblock calipers
Kevlar lines
Brembo RCS
Vortex Clip Ons
08 ZX-10R front wheel and rotors
Track bodywork (no idea what brand)
05 Swingarm with linkage
05 rear caliper
05 rear wheel with rotor and sprocket (have 3 different sizes)
Penske triple clicker shock
Dan Moto carbon slip on
Vortex rear sets
05-08 front fender
PC III

On the way/in progress:
oil change
coolant flush
remove emissions crap - Done
tune up/basic maintenance (including valve check) - done
finish bleeding brakes -done
03 ZX-6RR transmission, $153 shipped off eBay for the whole thing.
03 ZX-6RR slipper clutch, $76 shipped off eBay.

Need:
rear tire
paint
powdercoat frame, swingarm, subframe, rear wheel black (next winter I think)
slipper clutch (next winter when I do the powdercoat)

Pics:
When I bought it...


Working on it...



As she sits today before I take the bodywork back off to prep for paint (I do it myself).





Gonna be a lot of work over the winter, but whatever, should be fun! Thoughts, comments, criticism all welcome.
 

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Welcome! Bike looks darn good!!!
 

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wow, she's comin along very nice. you do some great work. can't wait to see it finished.

did you have any fitment issues with swapping parts from other bikes? i see you used the R6 calipers.
 

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Discussion Starter #7
wow, she's comin along very nice. you do some great work. can't wait to see it finished.

did you have any fitment issues with swapping parts from other bikes? i see you used the R6 calipers.
No issues, the thing with the calipers was that the R6 had 310mm rotors and the 6R has 300. But I used the spare front wheel and rotors off my 10R which also had 310mm rotors. So they mated up to the 05 6R forks perfectly and do not require spacers or grinding.

10r looks good. What yr?
Thanks man, 08... It is for sale too. Some of the parts are sold but I still have it pretty much stock now and still have all that bodywork too.

K now THAT is sexy!!! Keep posting pics!!
Thanks man, will do. I painted it myself, hoping this one comes out even better.
 

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Thank Heavens. It is about time that someone posted up a true bike build, not just "here is my slip on exhaust and tank pad". Keep up the good work man, and post more pictures!
 

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Discussion Starter #10
Thank Heavens. It is about time that someone posted up a true bike build, not just "here is my slip on exhaust and tank pad". Keep up the good work man, and post more pictures!
More pics as stuff happens/arrives. Thanks man.

badass. Hate the orange though...ever think of changing the color of the bike?
I bought the fairings used as you see them. I paid $150 shipped, don't worry it will get painted. I kinda like the orange though (even though I am a huge fan of Blue) but I have not decided what I am doing with it. I was drunk at a buddy's house one night and told him I would paint it like a plucked chicken (from the movie stroker ace) and put a sticker on it that says "fastest chicken in the south". I may do that for this year and then make it pretty next winter. Primary concern is getting it ready for the track, but rest assured, one day it will be pretty... just look at the 10r.
 

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Discussion Starter #13
Bitchin Bikes!!! I dig the 10R
Thanks!

if that 10R is anything to go by, your 636 will be superb

any details on the 10R?
The 10R is an 08 (for sale, mostly stock now) and I used it for street and track days. Since I did not want to crash the stock bodywork, I put it in the attic and got the race fairings and gas tank you see in the pic. Painted them myself and ended up never crashing the bike, so I suppose it was a waste of money. Oh well, cheaper than crashing stock plastics. I took off quite a few parts and put the on the 636 (Shock, brembo master, clip ons, spare front wheel). The 10R had a full stainless Leo Vince exhaust, the AK-20 forks (for sale to buy some for the 636), Galfer superbike lines which I traded my buddy for the ones on the 6, Pit-Eck bodywork, PC-V (for sale), and nobunaka rearsets. The bike was effing fast, but also caused me to develop some bad riding habits, so I am switching to the 6. I could also ride it on the streets by putting the mirrors back on and connecting my Piaa light.








I also have this bad boy... my 09 KX-450F.




now, back on topic...

Today my exhaust arrived for the 636 and I installed it. But after starting her up I think my far right cylinder is not firing, I will dig into that tonight. Better pics later, this is all for now.

 

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Discussion Starter #15
Well, #4 cylinder is getting spark, and fuel (plug was pretty wet) but it does not run right and when the bike is warm I can spray water on the headers and the #4 tube does not steam the water off right away so I can tell it isn't working right.

So I decided to run the bike with the airbox off so I can see what is going on. While running (no airbox) the #4 throttle body is shooting a fog of gas up out of the top. So... either the injector is stuck open and spraying everywhere, or one or both of the intake valves is messed up and the piston is shooting the gas back out. I need to borrow my buddy's compression tester and find out. If compression is good I will get new throttle bodies. If not, I will dig deeper. Whatevs though, I don't care... this bitch is gonna comply weather she wants to or not, even if I have to do a whole top end.
 

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wow, you put a lot of time and money into your bikes to do it right. I'm a fan, your 636 is going to look phenomenal. What MC are you running with the R6 calipers, the oem one? Just curious because i'm running spacers on my stock calipers to compensate for the bigger rotors but I might just switch over to the R6 calipers since we have a bunch laying around the shop
 

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bigdog, that is nice looking bike!
 

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Discussion Starter #20
wow, you put a lot of time and money into your bikes to do it right. I'm a fan, your 636 is going to look phenomenal. What MC are you running with the R6 calipers, the oem one? Just curious because i'm running spacers on my stock calipers to compensate for the bigger rotors but I might just switch over to the R6 calipers since we have a bunch laying around the shop

I am using a Brembo RCS master cylinder, the same one I had on the 10R before I put it back to stock. The 07 R6 calipers I am using do not require spacers with 310mm rotors and the 05 forks.

awesome build man going to be awesome
bigdog, that is nice looking bike!
Thanks guys.
 
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