Author Topic: 2003 Kawasaki ZX6R resurrection.  (Read 14872 times)

Offline IanC

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2003 Kawasaki ZX6R resurrection.
« on: October 18, 2013, 01:01:13 am »
Here's what I'm starting with.


Picked this up for $1800 on 10/17/13. I always loved the looks of the '03/'04 636 and they were pretty decent performers in their day. The goal of this build will be to have a nice daily rider and occasional track day tool.
 Cosmetically the bike has lots of issues but is at least mostly solid. Mechanically it seems pretty good. The test ride and ride home revealed a slight miss and low idle that I'll address soon. Noticed a 'rattle' off the clutch and heavy steering. Got it home and the chain was very loose. PO claimed to have replaced the chain recently and may have but if they did it was with junk. It's binding up a bit. Adjusted and lubed the chain so we'll see if that was my rattle tomorrow.  Checked the tire pressures to track down the steering issue and they were 30R/21F. Got to love used bikes.
So first step will of course be a tune up and a good once over. I've already made a long list of OEM part numbers to start shopping for. Stay tuned, I'll be updating this and adding pictures as I sort through and rebuild.

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Offline Deuce

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #1 on: October 18, 2013, 03:18:05 am »
 :pop
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Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #2 on: October 18, 2013, 03:23:01 am »
Hey, pssst, Ian....... that's not a 'Zuki man ....... :-[ what are ya doin buddy??? ...... ;)

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Offline 8Ball

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #3 on: October 18, 2013, 12:12:31 pm »
Hey, pssst, Ian....... that's not a 'Zuki man .......

And thus, it might actually have a working charging system!    :happypep
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Offline IanC

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Re:
« Reply #4 on: October 18, 2013, 01:05:23 pm »
Sadly true.
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Offline Deuce

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #5 on: October 18, 2013, 01:20:46 pm »
 :lol
2006 VTX1300C 205/70/15 Hydroedge rear tire, Leatherlyke Bags, Batwing, Cobra floor boards, Vance & Hines pipes, LEDGlow, Pair Mod, Kuryakin Hypercharger Pro, Mustang seat, Cobra passing lights, Cobra Case Gaurds, 3" Fork extensions, 1800C Shocks, Cobra Tach, Custom Risers, Custom Kickstand, and a  WOLO Badboy Horn.

Offline Marid2apterbilt

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #6 on: October 18, 2013, 03:33:54 pm »
And thus, it might actually have a working charging system!    :happypep

I think your confused w/ Honda.  :34
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Offline IanC

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Re:
« Reply #7 on: October 18, 2013, 06:03:50 pm »
The rattling is gone and the handling is much better now. Tune up and valve adjustment is next on my list.  I will be out riding Sunday A.M. to get used to the bike a bit more. Foothills is open so I'll probably head that way.
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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #8 on: October 19, 2013, 07:31:21 pm »
Ordered some parts today and picked up some plugs.  Swapping the plugs is much more time consuming than I've gotten used to. Other than being dirty everything looked good in under the air box. 


Found this IN my airbox. Scary stuff.


Need to get an air filter as it was filthy.  Played with the idle a bit and took it for a spin. Ran fantastic.  Gets better everyday. I did noticed a gear slip once though so a clutch job is in the cards soon too. I wanted to replace the clutch cover anyway.
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #9 on: October 20, 2013, 08:17:34 pm »
Took the 636 to the Hill this morning and did some Duc hunting.




They weren't really going that quick though. I took it easy and got familiar with the bike. I do need to undo the lowering that a PO did though, kept scraping my boots.
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Offline emd513

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Re:
« Reply #10 on: October 20, 2013, 08:25:45 pm »
Lol. How was the temp up there today

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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #11 on: October 20, 2013, 08:43:42 pm »
Not too bad. A bit chilly early in the morning.
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Offline Bobert

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #12 on: October 20, 2013, 10:07:56 pm »
Ian,
  That looks like it will be a great project, Keep posting the resurrection progress :21
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Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #13 on: October 21, 2013, 04:21:11 am »
looking good Ian ......now for the Race Techs, Ohlins, Brembo's, BST's and ceramic bearings ...
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #14 on: October 21, 2013, 08:50:24 am »
looking good Ian ......now for the Race Techs, Ohlins, Brembo's, BST's and ceramic bearings ...

You know me Dale, things are coming.
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #15 on: October 21, 2013, 08:30:03 pm »
Not too much to report today, spent some time adjusting the suspension to my weight per the service manual and adjusting the clutch. A suspension refresh/update is definitely in this bikes future.
1978 Suzuki GS1000EC - Completely custom.
2012 Triumph Daytona 675R

Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #16 on: October 22, 2013, 07:37:12 am »
Looking good son...I'm looking forward to seeing it in person next summer.
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Offline IanC

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Re: Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #17 on: October 22, 2013, 09:24:21 pm »
Looking good son...I'm looking forward to seeing it in person next summer.
Looking forward to it too.

Fixed the most annoying issue with the bike tonight.

Yes, the hanger was holding up the side stand.

New spring installed, lubed it up and Viola!
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Offline Curtie223

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #18 on: October 22, 2013, 11:54:39 pm »
Thats a first. Haha Never seen that before. Bet that was a pain to undo each time you made a stop. haha
I love these bikes. Best in the 600 class IMO. if ya need any help with it just give me a shout. The suspension and brakes are the best! and few race tech goodies and you will have an amazing handling bike. Oh and EBC HH sintered pads!

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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #19 on: October 23, 2013, 12:16:52 pm »
Side stand held up by a coat hanger...I think the idiot previous owner disqualified him or herself from ever owning a bike again right there!
« Last Edit: October 23, 2013, 04:56:13 pm by Chris »
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #20 on: October 25, 2013, 02:17:11 pm »
Picked up some stock shock links from EBay (new OEM links were $60 each!) and went about restoring the stock ride height.
Comparison between the Muzzys and the OEM links. The Muzzys are supposed to be adjustable for stock, 1 1/4" and 2 1/2" which I didn't find out until later but oh well, looks cleaner without extra link hanging out there.


OEM links installed.


I wish I had gotten a picture of the ride height with me on it before for a real comparison but I assure you that 2 1/2" makes a HUGE difference. It feels so much better now.
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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #21 on: October 27, 2013, 01:25:31 am »
Noticed I was missing the two upper front engine mount bolts.  I assume at one point it has frame sliders that were removed and the bolts weren't replaced.

So picked those nuts and bolts up along with the special mount adjuster socket and got those in there.  Turned out to be a huge pain in the ass.


While I had the plastics off I tinkered with them a little and they are on there much more securely. It'll do until I get the replacements.
1978 Suzuki GS1000EC - Completely custom.
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Offline Luvmystar

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #22 on: October 27, 2013, 06:45:48 am »
Glad your getting it sorted outIts amazing what some people think are not important.
Marc

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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #23 on: October 30, 2013, 08:23:16 pm »
Took care of another 'quality' bit of work from a previous owner.  The fairings were pretty loose because the ram air duct that acts as a fairing stay was gone and replaced with a few fancy pieces of thin aluminum.




Picked a new duct and the mounting hardware for it and the upper fairing stay.


The duct in place should actually net me a very small bit of power as it's very functional.


Everything installed.  It's much, MUCH more stable.  Looks a lot better too.


My plan is to make sure everything is right before I fork out for a new set of plastics and this was a huge part of that.  Stay tuned!
1978 Suzuki GS1000EC - Completely custom.
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Offline Luvmystar

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #24 on: October 30, 2013, 08:47:18 pm »
 :21
Marc

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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #25 on: October 31, 2013, 05:10:44 am »
Ian,

I'm thinking the bike is probably running much better with the restored intake ducting and of course the fairing is now much more solidly mounted.  Let's see, so far you've encountered missing engine mounting bolts, intake duct and fairing mounts, and the cheeziest of all, the coat hanger side stand retainer.  What a piece of work the moron previous owner is!  Any other total bodges to be repaired?

BTW:  Make sure to get it all sorted by summer so I can ride it, OK?   ;)

Dad
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Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #26 on: October 31, 2013, 05:46:52 am »
Looking good Ian !! Great work thus far ....
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #27 on: October 31, 2013, 08:11:25 am »
The ride to work this morning was pretty relaxed without having to hold my breath every time I hit a bump hoping the front end didn't drop. The bike seems a bit smoother now as well, especially at higher RPM's. So far that is pretty much it as far as 'WTF' repairs that I've found anyway. Well, there is one more that I found while doing the ducting that I'll be going back in there to fix soon. After that everything is pretty much standard pre-owned bike stuff. I'll be tackling the valves soon (shim under bucket, bleh), replacing the chain/sprockets, bearings, tires, getting some signals on it (scary not having them), replacing the rest of the missing trim, giving everything a thorough cleaning, replacing the plastics and then will dive into improving the suspension and brakes. A nice thing about this bike is that nearly everything I would want to improve was improved on the newer ZX6R's and can be used on my 2003.
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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #28 on: November 07, 2013, 11:35:14 pm »
The Kwak got a few more bits today.




 While I had the airbox off to change the plugs I noticed the air filter was filthy.



I was also missing a screw in the airbox lid.  I'm sure 9 was plenty but since it was supposed to have 10....



The little oil receiver was broken so went ahead and replaced it to.



While I have the tank and seats off I'm going to go ahead and remove the fairings tomorrow and do some cleaning.
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2012 Triumph Daytona 675R

Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #29 on: November 08, 2013, 07:30:09 am »
Feeling the love even way over here in Germany!  I just know that's a much happier motorcycle.


Well done.
CHRIS
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1978 GS1000C / 1979 GS1000S / 1981 CM400C / 1986 RG500 GAMMA / 1988 R100RS / 1991 K100RS / 1997 GSF1200 BANDIT