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Done for now, complete write up! 56k beware!

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33K views 50 replies 26 participants last post by  Maness1220  
T
#1 ·
Well after abour 5 months, its done so now i need to just buy a few mroe things, but i can ride it and it rides great! Here is the mod list, and i am sure i forgot some things, and there is also my soon to happen list lol

Mods:
-05 636 Bodywork
-06 r6 Tail and Subframe
-05 636 Calipers
-05 636 Forks
-05 636 Swingarm
-05 636 Shock
-03 636 Triple Trees
-CA Intagrated Tail Light
-RR Racing Gold Bar Ends
-RR Racing Gold Pegs
-Galfer SS Brake lines
-03 636 Pistons + Rings
-Bored Out Stock Cylinders
-Jet Kit
-K&N Filter and Oil Filter
-Ported Head with Reshaped Combustion Chambers
-03 636 Headers
-Yoshi Pipe Cut Down To About 11"
-Custom Frame Sliders
-05 636 Euro Signals Blue Tinted
-Changed Gearing -1+5 w/ Gold O-Ring Chain
-Euro ECU Box (yet to be installed but i have it)
-Pilot Powers F/R
-Custom Headlight Covers
-Painted Most Parts Including Frame, Swingarm, Wheels etc!

Parts Still Needed:
-Race Bodywork with Cut Headlights
-New Tial and Seat Cowl
-Hotbodies R6 Undertail
-Custom Paint in a Candy Blue with Black Lowers Tank and Tail
-Rear View Camera
-ZX7 Carbs
-New Headlight + Hids
-Carbon Fiber Fender and Hugger
-Gilles Rearsets
-SS Rear Brake Line
-Brake Line Switch
-Gold Pazzo Levers
and the list goes on and on, but thats the main stuff i need/want

Ok so here goes, pic frenzy of all my pics along the way, and remember, its not done, but its damn close enough!













More in second post!
 
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#2 ·


















Ok, now here is some info on the swap:
Forks:
i used 03 triples as i got them cheap, but you can use 03-05 stuff, just get the according rotors for the forks you are using. Just pressed out the stock stem out of the 03 triple, and pressed out the stock stem of the 98 triple and then presse din the stem to the 03 triple. Simple prosess, then you assemble with the stock bearings. You need to get a sleeve made or make a sleeve for the top triple so when you break hard it dosnt shift.

Tail:
Simple, used an 06 r6 tail, top mounts were ok, and i just tightend the bolts to strech the subframe the 1/2in or so on each side no big deal. You can see a picture of the braket i made so the lower bolt hole lined up. Need to perfect the idea, but it works just fine. Simple swap, i streched the tank to cover up the gaps near the seat better, but no big deal either.

Swingarm:
I am sure everyone read caddy's post about it, i helped him over pms on how to do it, and he took exact measurements, but i did it by eye and it worked out fine.

Fairings:
Simple, bolt holes almost line up besides for mid fairings, so i didnt use some, and i used my frame sliders as a mount too. Made a upper cowl faring stay that attaches to the stock 05 faring mount. Drilled 1 hole in the fairing mount for my guages and it works great. Ram air i need to plumb in but really no big deal. Wired up my headlights and rigge dup a high low thing as the prevous owner hacked the harness bad.

I think thats it, so shoot away with comments and questions!
Ben
 
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#6 ·
99Ninja6r said:
damn that looks great man! I'm surprised by how well the r6 tail flows with the rest of it. how's she run?
Click to expand...
runs good, need to adjust the valves, but it runs good, and i cant wait for the zx7 carbs, euro ecu and valve adjustment.
Ben
 
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#11 ·
e30kawi said:
what is the plan with the wheels?
Click to expand...
to replace them with marchesni rims at some point lol.

as for how much it cost, i spent about less then $1000 out of pocket with selling my old stuff and looking for good deals... The rest of the parts i want and need though are all out of pocket, so its going to get more expensive.
Ben
 
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#14 ·
yeah man, i got the 99 - 02 r6 tail, i love the feel, i dunno about the newer ones, but mine is so comfortable. the new one looks sick!!! is that subframe much different from the older ones? i had to make some brackets like yours on mine also, but it was the opposite... my brackets were on top, and the bottom needed some flaring.
 
T
#16 ·
yeah thanks everyone, and as for the subframe, get one and figure it out, not hard to do at all, anyone could do it, there is 1000s of ways to do it. Mine is setup so if i lay the bike down that i can just put the brackets on the new subframe if needed. Real comfy, got some good riding in today although it was hot. Rode about 100 miles now, and i can say it handles AWESOME! I am still displeased with the cosmetics but i am going to live with it until i can get some nice bodywork or unpainted bodywork, and do it right insted of dicking around with the broken shit. The bike flexes to much and the plastic and fiberglass break with little sress, so i am going to do a little bodywork here and there on it so it dosnt look so shitty, but really saving for new bodywork. I will get more pics once i get the anti freeze to stop pouring out the rad cap when it gets hot. Also got some engine ice to cool the temps and need to fix the fan as it dosnt work for some reason. Anyways, i will keep everyone updated!
Ben
 
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#19 ·
yeah i just came up with a sick idea for the paint, everyone will see soon enough, i was sitting down and got to thinking, and i really like the look of race bikes with number plates (as i want to hit some trackdays etc), but i want it streetable also, so i came up with a real cool idea of the right headlight of the 636 in 636 race fairings, and get number plates and headlight mesh, and make a number plate where 1 headlight would be and put the other number plate on the light and cut out the light in the plate and then use headlight mesh over the light, and make cut outs for numbers. Then use 1 hid and i should have plently of light. Use black headlight mesh on the tail light so it looks hidden also. Should be sick, hard to picture, but when its done it will be nasty! You guys will see! lol
Ben
 
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#21 ·
bars dont hit the tank, and the steering lock dosnt work right now, but i can make it work, just never cared as i never ever have used it. You need to make a new hole otherwise the bike is almost straight when the wheel is locked...
Ben
 
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#22 ·
just to confirm you used the 03 bottom yoke with your original stem pressed into it, then your original top yoke?
you also mention a sleeve for the top yoke, where does this need to go? and where would you need to put the new hole for the steering lock to work?
reason i ask is ive just bought a set of 04 forks with the bottom yoke, front wheel and braking assembly. and need to know what else i need to buy before i start trying to fit, so any advice you can offer will be much apreciated.
thanx :D
 
T
#23 ·
you need both triple clamps upper and lower, and you need to press in your origonal steering stem into the 03-06 stuff. You need to make a sleeve to fit inside the hole for the top triple and around the origonal 98-02 stem becuase it is not as big as the area in the top triple and when on hard breaking it moves (i found out the hard way)
Ben
 
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