03 636 track bike build thread - Kawasaki ZX-10R.net
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post #1 of 23 Old 12-06-2011, 03:51 PM Thread Starter
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03 636 track bike build thread

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

On the way/in progress:
Dan Moto carbon slip on
oil change
coolant flush
remove emissions crap
tune up/basic maintenance (including valve check)
finish bleeding brakes

Need:
rear tire
rear sets
05-08 front fender (what other years/models fit? zx-10?)
paint
powdercoat frame, swingarm, subframe, rear wheel black (next winter I think)
maybe power commander
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.

04 10R - My late brother's bike, will keep forever
03 636 - Track bike build in progress
92 Foxbody coupe, 5.0, 5spd.

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post #2 of 23 Old 12-06-2011, 04:01 PM
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since youre already doing a swapped front end, why not get a BPF from a new ZX6R? Just curious.
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post #3 of 23 Old 12-06-2011, 04:03 PM Thread Starter
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The triples are not the same. It would have been a lot more work to swap out for those and I think the AK's are better anyways.

04 10R - My late brother's bike, will keep forever
03 636 - Track bike build in progress
92 Foxbody coupe, 5.0, 5spd.

FASTEST CHICKEN IN THE SOUTH!
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post #4 of 23 Old 12-06-2011, 04:09 PM
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Was the swing arm a direct fit? Wheel base still the same?


Still pizzed at you for stealing MY motor!

( I have a line on two right now)

2011 Ninja 1K street
2004 636 track
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post #5 of 23 Old 12-06-2011, 04:20 PM Thread Starter
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Originally Posted by miykl View Post
Was the swing arm a direct fit? Wheel base still the same?


Still pizzed at you for stealing MY motor!

( I have a line on two right now)
Wheel base is supposed to be pretty much the same, within the adjustment range anyways. I did not measure first cause I was gonna do it anyways. A bunch of guys on the kawiforum have done it and said it is the same. It fit right up but you have to use the newer wheels, spacers, brake caliper bracket. This is gonna be a total frankenbike so I am sure I will be playing with the geometry a lot. I might have to ride yours once it is back together so I can see the difference and maybe use some baseline geometry numbers.

04 10R - My late brother's bike, will keep forever
03 636 - Track bike build in progress
92 Foxbody coupe, 5.0, 5spd.

FASTEST CHICKEN IN THE SOUTH!

Last edited by bird_dog0347; 12-06-2011 at 04:23 PM.
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post #6 of 23 Old 12-06-2011, 06:44 PM
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Originally Posted by bird_dog0347 View Post
I might have to ride yours once it is back together so I can see the difference and maybe use some baseline geometry numbers.
no worries.

2011 Ninja 1K street
2004 636 track
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post #7 of 23 Old 12-06-2011, 08:05 PM
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Coming together great lookin good. swingarm looks good on there and good call on stickin with the forks/ak kit the bpf swap would have been a pain with no gain. Itll look sweet with everything PCd black lookin forward to finished product

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post #8 of 23 Old 12-06-2011, 09:13 PM
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I had an 03 636 and loved that bike. But didn't you sell your 10 that was set up for the track? Why are you doing a 6 now?

2008 ZX-10R | Black | Arrow Headers | AreaP Slip-on CF | K&N Filter |GUTS ECU Flash By Guhl Motors | Block-Off Plates | Fender Eliminator | Clear Alternatives Integrated Taillight | Rifleman's 1/5th Throttle Insert | Speedohealer | Pro-Grip 719s | Vortex Bar Ends | Puig Z DB Windscreen | CBR1000 Mirrors | Vortex 520 Sprockets -1/+1 | RK Gold 520 Chain | Galfer SS Lines | Pazzo Shorty Levers | Vortex Gas Cap | Rebuilt Damper | Lightech Rearsets | Much More To Come
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post #9 of 23 Old 12-06-2011, 10:29 PM Thread Starter
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I had an 03 636 and loved that bike. But didn't you sell your 10 that was set up for the track? Why are you doing a 6 now?
The 10 is back to stock and still for sale. Some of the parts are left from it and are for sale.

A couple of reasons to go to a 6, first being cost... I still owe on the 10 and looking to lose the debt. I picked this up for a song, and won't be nearly as scared to wreck it (which should let me be a little more aggressive with it). Also I have adapted the park it in the corners, and shoot down the straight mentality... I have to learn to get faster in the corners, brake later, and accelerate sooner. That is easier to learn on a 6. I am just forcing myself to go fast with less power which should make me a better rider.

04 10R - My late brother's bike, will keep forever
03 636 - Track bike build in progress
92 Foxbody coupe, 5.0, 5spd.

FASTEST CHICKEN IN THE SOUTH!
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post #10 of 23 Old 12-07-2011, 04:58 AM
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Thats gonna be a very sweet tracker. Great work.

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