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Old 12-11-2010, 11:31 AM   #1 (permalink)
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Default Time to make some changes.

The poor girl has been touched up for the last decade, she needs a new look.

So the before....and the after is kinda planned, but not written in stone yet, but I am thinking all black to match my 10.

List of shit to do:

Fresh OEM big bore 636 kit(Euro spec)
Head cleanup with new adjustable cam sprockets(thinking 105/104-ish)
03/04 636 Fi conversion with race ECU
ZX9R clutch hub conversion to 5 spring
Black bodywork and frame
Racetek cartrige emulators for the front forks

So up for sale will be:
38mm carbs
636 pistons and block
(new)Dyna 2000 ignition with coil harness
.........pm for interest.
Attached Thumbnails
Time to make some changes.-rims.jpg   Time to make some changes.-stripped.jpg  
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Last edited by badassjake; 12-11-2010 at 03:03 PM. Reason: revision
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Old 12-11-2010, 11:36 AM   #2 (permalink)
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EEK, she's nekked!

My vote goes for the black, too. I'm hopefully tearing my ZZR down this winter and painting the frame black and adding an 07/08 swingarm for an updated look. I think I'll subscribe to this thread considering you pretty much have the same bike as I do, and I'm still looking for some ideas. LOL. Keep us up-to-date with whatever you do, man. Good luck!
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Old 12-11-2010, 02:08 PM   #3 (permalink)
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Keep us updated !
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Old 12-11-2010, 09:31 PM   #4 (permalink)
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Originally Posted by badassjake View Post
The poor girl has been touched up for the last decade, she needs a new look.

So the before....and the after is kinda planned, but not written in stone yet, but I am thinking all black to match my 10.

List of shit to do:

Fresh OEM big bore 636 kit(Euro spec)
Head cleanup with new adjustable cam sprockets(thinking 105/104-ish)
03/04 636 Fi conversion with race ECU
ZX9R clutch hub conversion to 5 spring
Black bodywork and frame
Racetek cartrige emulators for the front forks

So up for sale will be:
38mm carbs
636 pistons and block
(new)Dyna 2000 ignition with coil harness
.........pm for interest.

I have a Euro spec "kit" on the way, got the cylinders and pistons off the UK ebay for $280.00 shipped (the exchange rate really sucks). I should have them in the next week or so. According to the Kawasaki parts catalog the euro 636 pistons are different than the 03-04 636 pistons. I'm curious to see the difference.

I looked at the 03/04 Fi conversion but a few things concern me about it. The crank trigger wheel is different (may not be a big deal at all) but the sensor appears to be the same. The 03/04 has a cam position sensor, no provision on ours. Im curious how the fuel injectors will align with the runners on our head. The 03/04 has a different firing order (1243 vs 1234). Coolant temp sensor is different. When I hit the $500.00 mark on ebay parts I stopped looking. There is prolly a better solution for that kind of money.
It just looks like more work than I'm wanting to put into it at the moment. It would be nice to have a EFI setup though.
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Old 12-11-2010, 10:30 PM   #5 (permalink)
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-crank sensor bolts right on...shim the puckup farther out to align
-cam sensor is a slight tweak, but i'll post as I do that one, had to be creative to make it easy
-Fi ligns right up, have to used modded 03/06 intake boots
-1243 is the universal firing order for an inline 4, you may have confused it with cylinder order,as is printed on the Kawi materials
-coolant sensor need to be updated
other then that....LOL.....cake
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Old 12-12-2010, 07:53 AM   #6 (permalink)
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Quote:
Originally Posted by badassjake View Post
-crank sensor bolts right on...shim the puckup farther out to align
-cam sensor is a slight tweak, but i'll post as I do that one, had to be creative to make it easy
-Fi ligns right up, have to used modded 03/06 intake boots
-1243 is the universal firing order for an inline 4, you may have confused it with cylinder order,as is printed on the Kawi materials
-coolant sensor need to be updated
other then that....LOL.....cake
Hell yeah, man. An EFI setup would make me happier than a fat kid in a candy store. That's the number one biggest thing I wish my bike had. The 636 big bore kit sounds sweet as well. I think I'd like to do something like that and then sticker my bike as a "ZZR636". I like different. And why not go with a 636 motor swap? Just a matter of front engine mounts needing moved, airbox modification, and a wiring harness mod. That's all I can think up that would need to be done. Just seems like a complete motor swap out would be easier and less expensive. No?

Subscribed. This build is gonna be saaaweeeeet.
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Old 12-12-2010, 10:23 AM   #7 (permalink)
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yes and no....cheaper, yes. challenge, no......i'm a motor cycle mechanic by passion, so this stuff keeps me sane in the winter months.
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Old 12-12-2010, 11:23 AM   #8 (permalink)
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Subscribed. This build is gonna be saaaweeeeet.
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Old 12-12-2010, 11:51 AM   #9 (permalink)
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yes and no....cheaper, yes. challenge, no......i'm a motor cycle mechanic by passion, so this stuff keeps me sane in the winter months.
Hey man, whatever works for you. Either way, it'll be unlike any other's.
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Old 12-12-2010, 06:19 PM   #10 (permalink)
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Quote:
Originally Posted by badassjake View Post
-crank sensor bolts right on...shim the puckup farther out to align
-cam sensor is a slight tweak, but i'll post as I do that one, had to be creative to make it easy
-Fi ligns right up, have to used modded 03/06 intake boots
-1243 is the universal firing order for an inline 4, you may have confused it with cylinder order,as is printed on the Kawi materials
-coolant sensor need to be updated
other then that....LOL.....cake

I'm curious as to how you will work the cam sensor out. It shouldnt be too bad, the computer is probably just looking for one pulse every two crankshaft rotations.

Its good to know the injectors will align ok.

Coming from a car background I always thought the universal firing order for a inline four was 1342 since every car I have seen was that way. You are right about 1243 on the zzr I dont know why i had 1234 stuck in my head.

I look forward to seeing your project progress!
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