636 fork swap - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 239 (permalink) Old 01-26-2008, 02:50 AM Thread Starter
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636 fork swap

I'm swapping an '03 636 fork onto my 650, and I figured there might be some people on here that hadn't seen that done or might want to know how to do it themselves. I'm going to be doing most of this tomorrow, more pictures will be coming. The '03-'04 636 triples are supposed to be a direct fit, you can use the tubes and brakes from any ZX6R from 03-08. The 650 and the '05-'08 ZX6R use a 300mm petal style rotor, while the '03-04 use a 280mm rotor. I am planning on using the 300mm rotors by using 10mm spacers to space the calipers out to clear. I am planning on keeping the 650 wheel. The 650 and '05-'06 have an idententical wheel, besides the bearing sizes. The 650 uses a 42mm od, 20mm id bearing and the 636 uses a 47mm od, 25mm id bearing. The 636 uses a 25mm axle. To use the 650 wheel on the 636 front end I am going to use a 42mm od, 25mm id bearing. Both stock bearings are 12mm wide, while all the available 42/25 bearings are only 9mm wide, due to the fact that they use a smaller ball. To compensate for this I made some 3mm spacers out of 1" schedule 40 aluminum pipe. It has an id close to 25mm and the spacers should hold the bearings tight in the wheel along with the stock 636 collars.

The 636 bearing is on the left, the 42/25 is on the right:






Here is the spacer I made, along with the stock bearing and the new bearing with the spacer:





Here is how the stock 636 axle and hardware fit together:



Here is how it fits together with the smaller bearings and the spacers:



I should have more pictures and info tomorrow, hopefully everything goes together as planned!
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post #2 of 239 (permalink) Old 01-26-2008, 01:41 PM
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Looks awesome, speaking of retrofitting types of things, on the ninja650.com forums, someplace in Germany installs Z1000/636 tails on 650s that looks awesome. Any plans to maybe try this with instructions on how to do this? 636 beaten up tails aren't hard to find. It might have been the Z750 tail, but think its the same as the Z1000 and well 750 parts are impossible to find.
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post #3 of 239 (permalink) Old 01-27-2008, 04:28 PM Thread Starter
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Here is where I am at now:



My biggest issue is that I have no steering stops and my fork tubes hit the frame. I'll need to figure out what to do about that.

I have seen the Z1000 tail on a 650, it does look very nice, but spare Z1K parts are hard to come by. I am thinking about putting a Catalyst tail on my bike. I know its modeled after the 03-04 636, so maybe you could get one of those to fit as well, I don't know.
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post #4 of 239 (permalink) Old 02-06-2008, 01:46 AM Thread Starter
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post #5 of 239 (permalink) Old 03-25-2008, 12:00 AM
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That's a great build and it came out looking good too. How's handling feel versus the old setup?

Formerly Known as "Ken Yellow 02"
2008 Versys
2005 ZX-6R (Stolen 2/7/07)
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post #6 of 239 (permalink) Old 03-28-2008, 08:36 PM Thread Starter
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Once I got the suspension dialed in and set the sag it was a world of difference. It turns in better, overall a big improvement. The brakes are also a world of difference. The 650 has the same brakes as your Versys, they are ok, but not great. These radial mount calipers bite hard! I tore my bike apart this week and welded some steering stops to the lower triple to solve my issue:



I would definitely say it was worth it. There is more info on this swap here:

http://www.ninja650.com/phpbb/viewtopic.php?t=10167
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post #7 of 239 (permalink) Old 06-25-2008, 10:05 PM Thread Starter
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As an update, I have gone to using an 05-06 ZX6R wheel, my smaller bearings weren't holding up and I don't feel that was all that safe. Budget for a wheel if you plan to do the swap.

2007 Kawasaki EX650 street/track 636 forks - Hyperpro shock - Woodcraft - LeoVince - Dynojet
2003 Yamaha R6 race/track Ohlins - Arata - Vortex - Woodcraft - Dynojet
OMRRA Expert # 440
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post #8 of 239 (permalink) Old 06-25-2008, 10:07 PM
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post #9 of 239 (permalink) Old 06-26-2008, 12:03 AM Thread Starter
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Quote:
Originally Posted by hoser View Post
nice work jason
Thank you!

2007 Kawasaki EX650 street/track 636 forks - Hyperpro shock - Woodcraft - LeoVince - Dynojet
2003 Yamaha R6 race/track Ohlins - Arata - Vortex - Woodcraft - Dynojet
OMRRA Expert # 440
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post #10 of 239 (permalink) Old 03-10-2011, 08:17 PM
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So by what i am reding an 03-04 636 complete front end should just bolt up to my 650r.
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