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Basement Fighterer
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420 Posts
Discussion Starter · #1 · (Edited)
Winter 636 Build

I've been lurking around here for a week or two and finally picked up an 05 ZX636. The bike only has 8k miles but it was raced so I'm not sure what all I need to replace/check out. The bike was really dirty when I got it and it looks like there was some oil leaking in a couple places - not so bad it would drip, just enough that the dust sticks to it. Here are some pics after I washed it: (Not sure what the aluminum things are on the passenger pegs but they are not staying on)





I'm planning to go for a clean stockish look. I'll ride the bike to work about 25 miles each way so needs to be comfortable and reliable. I'll have a passenger once in awhile. The exhaust is in good condition so I'll probably leave the tail/subframe as is. Unless I want to reclaim some cash from that exhaust and put something cheaper on. The tail section is beat up so I will replace or repair.

For the front I'm doing dirtbike bars and headlight is TBD. I like the VROD headlight but I don't think it's edgy enough to match the rest of the bike. I will probaly cut down the Ram Air inlet on the frame unless I can find a way to work around it. If I cut the frame I'll also cut off any tabs that I don't need and hopefully have it powdercoated. Swingarm also needs replaced or powdercoated because it has some paint missing.

Not sure yet what I'll do with the paint, I'll decide later. For now I'm just going to take it apart and see what things need replaced and sell anything I can. Budget is tight I hope to be under $3500 total.

Wish list so far:

Front and Rear Tires
Matching Stator Cover
Dirtbike bars and risers
Different brake/clutch levers
Headlight
Chain and sprockets
Replace clutch (?)
Frame sliders
Stock rear turn signals to use with Two Bros Fender Eliminator
Front turn signals

I'm sure more things will come up as I go. This is my first fighter, had a few cruisers in the past. What do you guys think? I know it's going to be similar to Spyder's bike, his was the one that pushed me to go 636.
 

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Custom bikeporn addict.
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1,241 Posts
Those alu brackets on the passenger pegs may be saddle brackets? But why would you have those on a race bike? Maybe he used them for number plates?

Good platform to start with.

Bob
 

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up and coming fighterer
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292 Posts
Sounds like a good plan, looking forward to seeing all your progress. As far as the bike being raced, I myself would just go above and beyond with maintenance. Id replace the clutch and flush all the fluids, prolly replace pads and even tires.. I say clutch because I used to race motocross and my clutch took one hell of a beating. There are guys on here that I guarantee know specifics. Bike looks aggressive as is, it'll look great as a fighter.
 

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VP of Daily Operations
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7,472 Posts
love me some 05 636's do work buddy!!!! they have a bunch of potential... Mine has a couple stunt accesories but its still a super fun bike!!!

 

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Registered
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19 Posts
You shouldnt be too worried about the bike been on the track, looks like "chicken stips" on the back wheel.

Seems like the previous owner used is more as a trackday-bike, never raced with it. (no quick-shifter, street tires, no race fairings etc)

Clutches on these bikes dont take the same beating as motocross bikes. I would rather check the gearbox, shifting forks may get bent (examine the oil for metal).
 

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Basement Fighterer
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420 Posts
Discussion Starter · #6 ·
Thanks guys. The previous owner put 2500 miles on it and did not ride on the track. It was the one before him that raced it. I have some nOOb questions since this is my first sport bike so bear with me.

I've made a little progress on the bike. I need to get a stand and some better lights in my basement before I get too crazy but I've pulled off the aluminum passenger peg things.

The reason I mentioned the clutch before is that the bike seems a little grabby when slipping the clutch. I didn't know if this is normal but it doesn't take off as smooth as the other bikes I've had. Would that mean the clutch is bad? Doesn't seem to slip under power just kinda lurches when I take off from a stop.

My second question is about the brakes. Both the front and rear brakes engage way late in the travel. The bike stops fine but the front brake can be squeezed to the handlebars on probably 4 of the 6 adjustment settings. Pads look OK. Are the brakes meant to engage late in the lever travel?

Last thing, I have a couple places where oil has leaked a bit. Anybody have input on this? I'm not sure how often the bike was cleaned before I bought it so maybe the oil has seeped out over a long period of time (?).

RH side of motor:



LH side of motor:



I want to get the maintenance / repair stuff ironed out before I move forward with the mods so I can make sure I have the money to do what I want.
 

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Asphalt cowboy.
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549 Posts
Those 636's are TANKS man!

Bonnie, after returning from Nova Scotia.



I sold her recently, to get a ZX10R which I'm pretty much turning into the same thing.

I bought her new & proceeded to crash her four times. My buddy I sold her to ate a T intersection at near top speed so she's back in the garage & so far, looks like she'll come back a fifth time.

Any details ya want, lemme know. I know that bike inside & out.
 
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Bitches love Fighters
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5,325 Posts
bleed the brakes until fresh fluid comes out and you shouldnt be able to touch the grip anymore. and those little dirty spots are nothing to worry about. just clean them up.
 
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Basement Fighterer
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420 Posts
Discussion Starter · #9 ·
I started the teardown tonight. Nothing much to add other than the exhaust is in pretty mint condition besides some tar that was thrown up from the tire. Any suggestions on what to use on the CF cans and stainless(?) mid pipe to get the tar off? I have some bug and tar remover but I don't wanna screw up the carbon fiber.

Pic:



I'm thinking about colors a little more. I'm thinking of doing silver vein powdercoat on the frame and swingarm then maybe going white on the tank and tail. Covers and other accents could be gunmetal colored like the wheels. I'm just not sure if it would be too many colors with the gold parts. Anybody good with photoshop?

 

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Basement Fighterer
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420 Posts
Discussion Starter · #10 ·
Pulled some parts off to hopefully sell soon. I might have ruined the windscreen though. :doh: There were some decals on it and I had some carb cleaner laying around.... Bad idea. I'm going to try some PlastX and see if I can polish it back to a shiny finish.

Looks good naked :CK187:



I'm thinking the silver vein powdercoat might be too much now. Not sure if it would look as clean as I want.
 

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Basement Fighterer
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420 Posts
Discussion Starter · #12 ·
Had some more time to tear into the bike. Soon I'll be able to pull the motor and get it ready to paint. I've decided to go with white for the tank and tail but I'm not sure what I'm doing with the frame/swingarm and engine yet. I'm a big fan of gunmetal gray but not sure where to use it yet.





 

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Basement Fighterer
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420 Posts
Discussion Starter · #13 ·
I ordered my headlight and got it in. Here are some pictures of the mock up:







Looks like I'll have to relocate the ignition switch so I can tuck the tach in behind the headlight. Should look awesome when it's done but I have no idea where I'll put the ignition. It's hard to tell where it would fit now that everything is tore apart.

Still debating on colors. I'll probably go white or gunmetal. I need to check with the vinyl wrap guys because I have an idea I want to see if they can do.

Here's where I left the bike. I'm gonna spend the next few weeks cleaning everything, pulling the motor, and selling parts to get new parts. Don't have any more money to throw at it for awhile unless I sell shit. (I have stock headlight, clip ons, front fender and lots of other stuff, PM me if you need anything.)

 

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Basement Fighterer
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420 Posts
Discussion Starter · #14 ·
Finally got back to doin' some work. I tore off all the brackets, masked off what I could, and pulled the motor:



Lugged the motor from my basement to my garage, I felt just like one of those guys in a strongman competition. I built a little stand to hold the motor up:



Scrubbed the motor with engine degreaser and a little brush, 2 cans of non-chlorinated brake cleaner, soap and water with same little toothbrush, and a final cleaning with some 3M adhesive remover.... The paint better stick I'd eat off this fucker.



Duplicolor primer and engine enamel. Not sure if I like the color now I wanted it to match the wheels a little closer. I need to get it out in the light and see it next to all the gold parts on the bike. I was going to stay with the bronze colored stator and clutch covers but I don't know if they will go with this gray. Might end up scuffing and re painting. :shootme:

Light on


Light off
 

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Basement Fighterer
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420 Posts
Discussion Starter · #17 ·
Yea I'm definitely repainting. I had to move the motor from my garage to my basement because it was too cold for the paint to cure. Hope to paint tomorrow or next weekend. I'm thinking I'll probably do an aluminum silver color with black powdercoated covers. My stator cover is dicked up anyway so the PC will cover it up fine.

I think if I go black for the motor there will be too much black since my frame, swingarm, rearsets, triple trees, and any other little bracket will be powdercoated gloss black plus the headlight and front fender are gloss black.

Here's a photochopped bike that's pretty close to what I'm going for.

 

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Basement Fighterer
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420 Posts
Discussion Starter · #18 ·
Ok I fixed my paint screwup. No more picking out paint or parts when I'm hungover!





3 of the side covers plus the oil pan will be powdercoated gloss black. Not sure yet if I'll PC the radiator black or match the engine paint.
 

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Basement Fighterer
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420 Posts
Discussion Starter · #19 ·
It's been awhile since I posted. I've made some progress and had some fuckups. After I repainted the engine I ordered a top triple clamp for an 07-08 ZX6-R so I will have a solid mount for my dirt bars:



I'm going to CNC mill the clamp to fit my needs - cut off ignition mount, drill for risers, cut off boss on bottom to drop it about 1/4". When it's done my gauge cluster will fit right in front of the triple, tucked behind my headlight cowl.



I picked up some Pro Taper Mini Low bars, risers, knock off gold levers, gel grips, and a CRG bar end mirror. Next week I should have my triple machined and bars fit up. Not sure yet if I'll have to get new front brake lines. I think I'm going to move the ignition switch (minus keyswitch and fork lock) under the passenger seat and route the battery wire thru the kill switch. Here's what the ignition switch looks like without the housing and fork lock - nice and compact just need to keep it from getting wet.



I've had some trouble with dropping shit with this project. I left my headlight taped in place on the forks and found it on the floor broken the next day (fuck you blue masking tape!). Also dropped my mint front fender and scuffed it up.

Color wise I decided to go with a matte pearl white (toyota / lexus) for the tank and tail. I'll leave the front fender and headlight cowl black. Frame and swingarm got powdercoated gloss black along with some of the miscellaneous brackets. The engine covers and oil pan have been powdercoated a metallic bronze and the wheels might get the same when I change tires.

I spent some time cleaning out the blasting media from the engine covers. This stator cover was rashed pretty bad but I sanded it out really nice.



The rest of the parts:



There's still a little grit in the clutch rod bearings in the clutch cover. I'm going to change my oil at 500 miles and if the bearings still sound shitty I'll replace then.

Picture of engine with covers installed. The color is preety sweet, it's more of a subtle bronze than the stock color.



Here's a picture of the Auto Zone bearing puller I used to get the swingarm bearings out of my old swinger. I was able to salvage 3 out or 5, two of them didn't have a big enough lip for the puller.



And here's a picture of the goodies waiting to get installed.



Hope to finish in the next couple weeks.
 
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