Ok, there is always millions of questions on what fits what and they almost all have been discussed. But i think if this is made a sticky, it will keep a bunch of un-needed threads from being made when the info is right there. Anyways, Here goes, i have tried a bunch of this stuff to confirm it, and its also a conglomeration of other members info as well such as Badassjake and Brijesh600 etc!
03/04 636 Parts:
-Gauge Swaps over with slight rewiring of the plug, more info here:
http://www.kawiforums.com/showthread.php?t=82684
-Swingarm Swaps over to a 98/99 for an updated "Knife-Edge" look, and also works on the 00-02 but is the same but has an extra hole or two for the hugger which also enables you the option to use more/better looking huggers.
-Forks, they swap over with the change of the stock steering stem of your bike pressed into the lower triple tree to the 03/04. To use your stock rim and or rotors, you need the corresponding spacers, and if you use the 98-02 rotors you need 10mm spacers for the brake calipers and longer bolts as the rotors are larger then the stock 03/04 rotors. You will also need a bushing made for the upper triple clamp that goes around the steering stem but inside the top triple. For the key switch you will need to trim down the size of the ignition posts on the upper triple clamp so you can still use the steering lock. OEM clip ones will not work, they are too small, use the 03/04 ones, and the 03/04 fender is different then the 98-02 fender.
http://www.kawiforums.com/showthread.php?t=56751
-Subframe/Tail Swap, common swap where the subframe needs to be re-welded a little wider on the top mounts or a bracket needs to be made. You need all the parts off the 03/04 for the swap if you want to do it correctly. But with the slight re-weld of the mounts it can be bolted on, but IS NOT a bolt on item. http://www.kawiforums.com/showthread.php?t=23265
-Engine, the engine and wiring and throttle bodies etc do bolt in the frame, yes its true, i have it done, but the front engine mounts DO NOT line up, and you WILL NEED some welded to the frame which is actually a very simple job for a good welder/machine shop. The airbox plate needs to be modified for the throttle bodies as does a hole for the air temp sensor, but can be done, or pods can be used but ram air effect will be lost. The fuel pump is another issue as the OEM one does not pump enough for the engine to even start. You can use a automotive and a regulator, or you can use the 03/04 tank (read below for more info on tank)
-Gas Tank, will fit with a hole drilled and tapped in the center of the front of the frame. You will need to make a rear tank mount as well, but the tank fits nicely on the frame with some work and a spacer up front. I do not suggest this unless you do a engine swap as then you need to worry about the fuel pump as its much more powerful then the OEM one. Your OEM 00-02 Cap WILL bolt on, but the 98/99 cap WILL NOT bolt on.
-Wheels, they will bolt up with the correct spacers as they are pretty much identical EXCEPT THE FRONT RIMS HUB IS WIDER, AND REQUIRES THE 05/06 ROTORS AS THEY ARE NOT OFFSET AND THEY ARE THE CORRECT DIAMETER FOR THE BRAKES, but its easy. Cush drive is the same as the 98-02 on the 03/04 and as is the rear rotor. Bolt on item here.
-Shock, can be swapped, is slightly different then the 98-02, but is a direct bolt on, not sure of the advantage or disadvantage.
-Radiator, can be swapped over, the top mounts are the same, temp sensor is different and needs an adaptor made for yours to bolt on. It is physically smaller then the 98-02 but it works as well. Lower brace for the side panels will not bolt on it as its smaller but the top will mount fine which is plenty of mounting for it.
-Pistons, can be used in the 98/99 by boring the cylinders and reshaping the combustion chamber (Badassjake does this), and it provides increase in power, and the 00-02 can be swapped over with just a bore and re-plate of cylinders as they are coated, but the head is the same shape as the 03/04 so no worries there.
-Headers, bolt directly on, better design, and more options for exhaust.
05/06 636 Parts:
-Forks, same as the 03/04 except that the front rotors are the same size as the 98-02 ones so no spacers needed in the swap down there but up on the top triple the same thing is needed. You can mix and match as well the 05/06 forks work with the 03/04 triples and you can use a lower off a 05/06 and a upper off a 03/04 or visa versa. You can use your OEM axle and wheel on these with the OEM spacers with no issues at all. The front fender is different then the 03/04 so you will need the correct fender. Clip ons are obviously needed as the stock ones are too small.
-Subframe, can be made to fit, Brijesh600 did the swap but he made a set of adaptor plates for it, and used the Lazer exhaust. More info go here:
http://www.kawiforums.com/showthread.php?t=70386&highlight=my+undertail+exhaust
-Swingarm, bolts right up, slightly longer then stock. Shock and linkage is also needed as OEM hits the swingarm. The rear wheel needs to have the spacers cut down and the 05/06 caliper bracket cut down or custom made to accommodate the extra with of the rim. The 05/06 rear rim is a direct bolt on if you do this and keeps it simple. The exhaust cover on the arm does not fit with the rearsets so you will need to take it off for clearance issues, but no problems there.
-Wheels, the front is a bolt on with the correct wheel spacers and the stock/aftermarket rotors for the bike. The rear needs a bunch of spacers and adaptors and is much easier with a 05/06 braced swingarm swap. Wheel is much skinnier then the OEM one so spacing for everything is needed.
Misc parts that fit:
-ZX10R shock, linkage needed, but bolts on stock arm or 636 arm, much better for 150-180lbs riders, but 636 Shock better for 180+lb riders.
-ZZR fairing stay, bolts right up on the 00-02 and removes the "Bird Cage" older one, also will fit a 98/99 but you will need a new gauge cluster from the 00-02/05-08 zzr 600, and you will need to rewire for the cluster, but hey while your at it, why not swap over to a 03/04 cluster?
-00-02 to 98/99 fairing swap, the upper is the only different plastic part besides the air intake and windscreen. You will need upper, headlight, wiring for light, 00-02 gauge (for simplicity) and headlight stay or a ZZR one so you don't need the "Bird Cage" OEM one and a gauge stay, cuts down on parts needed as well if you use the ZZR Stay.
-06 R6 Tail swap, bolts right on the upper subframe mount, but you need to make a lower mount which can be easily bolted on and be adjusted for correct tail height. Seat lines up with tank with some work, but the Subframe bolts up pretty easily. Problem i ran into was there is not exhaust hanger, but other then that, its a very different mod.
MORE PARTS ADDED SOON, FEEL FREE TO ADD THINGS I AM MISSING, BUT KEEP THREAD TO INFO NOT QUESTIONS PLEASE.
03/04 636 Parts:
-Gauge Swaps over with slight rewiring of the plug, more info here:
http://www.kawiforums.com/showthread.php?t=82684
-Swingarm Swaps over to a 98/99 for an updated "Knife-Edge" look, and also works on the 00-02 but is the same but has an extra hole or two for the hugger which also enables you the option to use more/better looking huggers.
-Forks, they swap over with the change of the stock steering stem of your bike pressed into the lower triple tree to the 03/04. To use your stock rim and or rotors, you need the corresponding spacers, and if you use the 98-02 rotors you need 10mm spacers for the brake calipers and longer bolts as the rotors are larger then the stock 03/04 rotors. You will also need a bushing made for the upper triple clamp that goes around the steering stem but inside the top triple. For the key switch you will need to trim down the size of the ignition posts on the upper triple clamp so you can still use the steering lock. OEM clip ones will not work, they are too small, use the 03/04 ones, and the 03/04 fender is different then the 98-02 fender.
http://www.kawiforums.com/showthread.php?t=56751
-Subframe/Tail Swap, common swap where the subframe needs to be re-welded a little wider on the top mounts or a bracket needs to be made. You need all the parts off the 03/04 for the swap if you want to do it correctly. But with the slight re-weld of the mounts it can be bolted on, but IS NOT a bolt on item. http://www.kawiforums.com/showthread.php?t=23265
-Engine, the engine and wiring and throttle bodies etc do bolt in the frame, yes its true, i have it done, but the front engine mounts DO NOT line up, and you WILL NEED some welded to the frame which is actually a very simple job for a good welder/machine shop. The airbox plate needs to be modified for the throttle bodies as does a hole for the air temp sensor, but can be done, or pods can be used but ram air effect will be lost. The fuel pump is another issue as the OEM one does not pump enough for the engine to even start. You can use a automotive and a regulator, or you can use the 03/04 tank (read below for more info on tank)
-Gas Tank, will fit with a hole drilled and tapped in the center of the front of the frame. You will need to make a rear tank mount as well, but the tank fits nicely on the frame with some work and a spacer up front. I do not suggest this unless you do a engine swap as then you need to worry about the fuel pump as its much more powerful then the OEM one. Your OEM 00-02 Cap WILL bolt on, but the 98/99 cap WILL NOT bolt on.
-Wheels, they will bolt up with the correct spacers as they are pretty much identical EXCEPT THE FRONT RIMS HUB IS WIDER, AND REQUIRES THE 05/06 ROTORS AS THEY ARE NOT OFFSET AND THEY ARE THE CORRECT DIAMETER FOR THE BRAKES, but its easy. Cush drive is the same as the 98-02 on the 03/04 and as is the rear rotor. Bolt on item here.
-Shock, can be swapped, is slightly different then the 98-02, but is a direct bolt on, not sure of the advantage or disadvantage.
-Radiator, can be swapped over, the top mounts are the same, temp sensor is different and needs an adaptor made for yours to bolt on. It is physically smaller then the 98-02 but it works as well. Lower brace for the side panels will not bolt on it as its smaller but the top will mount fine which is plenty of mounting for it.
-Pistons, can be used in the 98/99 by boring the cylinders and reshaping the combustion chamber (Badassjake does this), and it provides increase in power, and the 00-02 can be swapped over with just a bore and re-plate of cylinders as they are coated, but the head is the same shape as the 03/04 so no worries there.
-Headers, bolt directly on, better design, and more options for exhaust.
05/06 636 Parts:
-Forks, same as the 03/04 except that the front rotors are the same size as the 98-02 ones so no spacers needed in the swap down there but up on the top triple the same thing is needed. You can mix and match as well the 05/06 forks work with the 03/04 triples and you can use a lower off a 05/06 and a upper off a 03/04 or visa versa. You can use your OEM axle and wheel on these with the OEM spacers with no issues at all. The front fender is different then the 03/04 so you will need the correct fender. Clip ons are obviously needed as the stock ones are too small.
-Subframe, can be made to fit, Brijesh600 did the swap but he made a set of adaptor plates for it, and used the Lazer exhaust. More info go here:
http://www.kawiforums.com/showthread.php?t=70386&highlight=my+undertail+exhaust
-Swingarm, bolts right up, slightly longer then stock. Shock and linkage is also needed as OEM hits the swingarm. The rear wheel needs to have the spacers cut down and the 05/06 caliper bracket cut down or custom made to accommodate the extra with of the rim. The 05/06 rear rim is a direct bolt on if you do this and keeps it simple. The exhaust cover on the arm does not fit with the rearsets so you will need to take it off for clearance issues, but no problems there.
-Wheels, the front is a bolt on with the correct wheel spacers and the stock/aftermarket rotors for the bike. The rear needs a bunch of spacers and adaptors and is much easier with a 05/06 braced swingarm swap. Wheel is much skinnier then the OEM one so spacing for everything is needed.
Misc parts that fit:
-ZX10R shock, linkage needed, but bolts on stock arm or 636 arm, much better for 150-180lbs riders, but 636 Shock better for 180+lb riders.
-ZZR fairing stay, bolts right up on the 00-02 and removes the "Bird Cage" older one, also will fit a 98/99 but you will need a new gauge cluster from the 00-02/05-08 zzr 600, and you will need to rewire for the cluster, but hey while your at it, why not swap over to a 03/04 cluster?
-00-02 to 98/99 fairing swap, the upper is the only different plastic part besides the air intake and windscreen. You will need upper, headlight, wiring for light, 00-02 gauge (for simplicity) and headlight stay or a ZZR one so you don't need the "Bird Cage" OEM one and a gauge stay, cuts down on parts needed as well if you use the ZZR Stay.
-06 R6 Tail swap, bolts right on the upper subframe mount, but you need to make a lower mount which can be easily bolted on and be adjusted for correct tail height. Seat lines up with tank with some work, but the Subframe bolts up pretty easily. Problem i ran into was there is not exhaust hanger, but other then that, its a very different mod.
MORE PARTS ADDED SOON, FEEL FREE TO ADD THINGS I AM MISSING, BUT KEEP THREAD TO INFO NOT QUESTIONS PLEASE.
I wish I would've known I could get the 03+ to work w/o much work. I like them a whole lot better.
