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post #1 of 100 (permalink) Old 01-21-2012, 02:32 PM Thread Starter
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636 Fighter Project

I picked up an 05 ZX636 last fall and I've been slowly working on it. I've gone far enough now that I though I'd make a thread to show my progress and ask some questions.

Plans for the bike include cleaned and painted motor, cleanup frame (take off tabs I don't need and fill in any holes I won't use), gloss black powdercoat frame swingarm and other various parts, white paint on tank and tail, aftermarket headlight, 09 front fender, dirt bike bars and risers, shorty levers, relocate ignition, jumper mod, and any other maintenance stuff that comes up.

Here's what the bike looked like when I brought it home. I've sold some of the parts on here and I have others I'm still trying to sell so let me know if you see something you need.





I found out those aluminum things on the passenger pegs are fender supports for a VTX 1300. Kinda weird.

After putting a few miles on the bike to check everything out I drove it into my basement and started tearing everything down.







I picked out a headlight and fit it up. I'll have to do something with the ignition so I can squeeze the gauges in behind the headlight. And I'll have to chop the ram air inlet off the frame so the headlight can fit closer to the forks.





I bought an 09 front fender because I think they look sweet. I've started fitting it up - it needs to be trimmed to clear the mounting brackets on the forks and I'll have to make some adaptor brackets. But here's how it will look - the front fender matches the headlight pretty well, both have a little bit of metallic flake in the plastic.





I think I'll leave the headlight and fender black and paint the tank and tail white. The frame, swingarm, triple clamps, and any other little brackets I take off wil be powdercoated gloss black. I'm wondering how the wheels will look with those colors, if I don't like them I might sell and try to pick up some black 09+ wheels.

Last weekend I pulled out the motor for paint. It didn't seem that dirty but it took forever to clean before I painted it with Duplicolor Engine Enamel. Now I'm not sure if I like the color so I'm thinking about scuffing up the paint and either going with an aluminum silver or black.







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post #2 of 100 (permalink) Old 01-21-2012, 02:39 PM
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i like it.
make it yours, but expect to be flamed for being different...

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a beer-drinking, pot smoking, naked bike trashing hillbilly like you has an iPOD Touch ??--cobra
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"Blah blah my bike is faster than yours around a technical track". Yawn. Well I on my feet can beat your small bike in a race of 100 laps around my couch
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post #3 of 100 (permalink) Old 01-21-2012, 02:45 PM Thread Starter
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I have a few questions for you guys....

What options do I have to get away from the tall fork adjusters? They will force me to raise my handlebars pretty high to clear them, I'd rather get some shorter adjusters or trade out forks. I've heard 07-08 forks would fit my stock triples - is that true? Looks like they don't stick up as far.

If I swap out forks I'll probably think pretty hard about going away from the gold. I think it might be too many different colors once I have white, black, gray wheels, whatever color the engine ends up being... I like clean and simple.
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post #4 of 100 (permalink) Old 01-21-2012, 02:54 PM
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not sure about the 07-08 tubes. just get taller risers or slide the forks down the triples a lil bit. it's not like you're building a track bike.

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a beer-drinking, pot smoking, naked bike trashing hillbilly like you has an iPOD Touch ??--cobra
Quote:
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"Blah blah my bike is faster than yours around a technical track". Yawn. Well I on my feet can beat your small bike in a race of 100 laps around my couch

Last edited by locknload; 01-21-2012 at 02:56 PM.
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post #5 of 100 (permalink) Old 01-21-2012, 04:17 PM
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Wow, I like the project! Looks good keep it up and keep us in the loop. Good luck with the build!

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post #6 of 100 (permalink) Old 01-21-2012, 04:26 PM
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Looks good so far, I love that headlight assembly


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post #7 of 100 (permalink) Old 01-21-2012, 09:48 PM
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Any concerns about blocking the ram intake?
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post #8 of 100 (permalink) Old 01-21-2012, 10:25 PM Thread Starter
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Appreciate the comments!

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Originally Posted by locknload View Post
not sure about the 07-08 tubes. just get taller risers or slide the forks down the triples a lil bit. it's not like you're building a track bike.
I don't want it to look like I had to work around the adjusters. I want the bars and forks to be where I want them and not where they have to be. I'm pretty sure I'll be able to sell my forks and buy a different set without spending much money. I am on a budget.


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Any concerns about blocking the ram intake?

Nah I've heard of people doing this without much trouble. I'll lose some power at higher speeds but that's fine with me.


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Looks good so far, I love that headlight assembly
Me too I think it flows pretty good. It's from Unique Moto Lights .com - theres a halo around the bottom, can't wait to see how it looks all lit up.

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post #9 of 100 (permalink) Old 01-21-2012, 10:45 PM
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when i drilled the top triple on my YZF, i had a similar problem. i also didn't want to move the forks so i just drilled the holes a little farther back & made short spacers for the risers.
BTW: i have some experience with streetfighters, this is my '00 12R (sold).



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Quote:
Originally Posted by dwillits View Post
a beer-drinking, pot smoking, naked bike trashing hillbilly like you has an iPOD Touch ??--cobra
Quote:
Originally Posted by Barry Soetoro View Post
"Blah blah my bike is faster than yours around a technical track". Yawn. Well I on my feet can beat your small bike in a race of 100 laps around my couch
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post #10 of 100 (permalink) Old 01-21-2012, 11:18 PM Thread Starter
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Yea I've seen that bike in another thread it's pretty badass. If I use my stock triple clamp the handlebar will run right over the forks because I'd use the holes that are already in the triple clamp.

Maybe I'll get this clamp and I'll cut off the ignition mount and drill mounting holes:

Yana Shiki Billet Top Triple Clamps LRC Engraved Kawasaki ZX6R - Indysuperbikes
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