Author Topic: 2003 Kawasaki ZX6R resurrection.  (Read 15667 times)

Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #30 on: November 08, 2013, 09:12:46 am »
All your work is great Ian !! But you seem to have a small problem you might want to check into ..... your hands are blue ...... :whistle
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Offline IanC

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Re: Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #31 on: November 08, 2013, 09:18:50 am »
All your work is great Ian !! But you seem to have a small problem you might want to check into ..... your hands are blue ...... :whistle

It was extremely cold in the garage.
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Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #32 on: November 08, 2013, 09:27:12 am »
Ahhhh, I see.......maybe get a heater ..... ::)
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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #33 on: November 08, 2013, 02:34:37 pm »
After stripping the rest of the body off the 636 was rolled outside for a thorough cleaning.
Before:




After:

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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #34 on: November 08, 2013, 08:40:46 pm »
Buttoned everything back up. Ditched the fairing mounting 'hardware' a P.O. had holding everything up which consisted of random crap and dug into my nut and bolt bins which apparently are much nicer than the P.O.'s nut and bolt bins. Added hardware that was missing, tapped a hole on the frame that had buggered threads and lubed the chain. I have a line on the parts needed for my next bigger project so stay tuned for that.
« Last Edit: November 08, 2013, 08:41:11 pm by IanC »
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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #35 on: November 08, 2013, 09:49:19 pm »
Looking good son.  Good work!
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Offline Chris

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2003 Kawasaki ZX6R road test
« Reply #36 on: November 18, 2013, 05:40:47 am »
Ian,

I found this road test of your bike at the Visor Down website from Britain. 

Enjoy.

Dad




Kawasaki ZX-6R Ninja B1H-B2H (2003 - 2004)
Reviewed: by Visordown

pros:
 
No holds barred 600 race rep for the road, it put Kawasaki firmly back on the map. Comes in to to its own on the track. The 636 B models are still renowned for their focused and flighty attitude.
 
cons:

Cramped riding position and track focused performance may prove too inflexible for the road.


You can see the influences from both the ZX-10R and MotoGP ZX-RR machines. The new 6R has a low screen and flowing contours all the way back to the tail unit, then up close the smooth curves of the nose, lights and front mudguard go some way to justifying Kawasaki’s claim that this is the most aerodynamic Ninja to date. With everything pulled in, rear turbulence has been greatly reduced behind the rider, adding to comfort and top speed. The speedo reading rose from 156mph to 165mph in a few seconds just by tucking in properly, which suggested the slippery shape was working well.

Other nice touches are the nicely engineered pillion peg mounts, integrated indicators and lighter ZX-10R-style wheels. The underseat muffler is less tidy and protrudes more than the CBR 600RR’s, but looks good never the less.

On to the fun part. After hopping aboard I found the riding position for me was a tad cramped. The pegs didn’t give me enough legroom, being a touch too high and forward, plus the brake and clutch levers were set too high. The clutch lever will move down but the brake line connections make it difficult to adjust the right hand lever. I admit after riding for a while I got used to these niggles, but were I to own this bike I would make minor alterations to make riding more comfortable.

Its best feature though is the free-revving, 130bhp motor (claimed, and 136 with ram air effect), which starts with a wail around 8000rpm then develops into a full banshee scream en route to the 15,500rpm rev limit. There is no definite powerband but also no boring linear feel either; just a great engine that will never fail to set your pulse racing.
The extra engine performance comes from a combination of new, 38mm oval throttle bodies (keeping the frame slim), bigger intake and exhaust valves, new camshaft profiles and an integral exhaust valve.


Read more: http://www.visordown.com/reviews/motorcycles/sportsbikes/kawasaki-zx-6r-ninja-b1h-b2h-2003---2004/review/27.html#ixzz2kzXWzW9R
« Last Edit: November 18, 2013, 05:44:04 am by Chris »
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #37 on: November 18, 2013, 10:46:40 am »
Thanks for sharing that. The horsepower rating was a bit of an embellishment in the article, the 03/04 put a realistic 110hp to the ground. My only qualm with this bike after riding it for a bit is that it really should have come fitted with a steering damper and will get one. When the front end gets light at the top of the tach the steering wants to start slapping about. The riding position isn't horrible but if I ever do much track time I'll have to get rear sets. Even at just 5'10" it's nearly impossible to get into a full tuck. Obviously nothing I'm concerned about for the street.
Also, the brakes on this bike have always been applauded and I do love them, they have good feel and solid bite from start to finish. Today I got a reason to really put them to the test when a little old lady pulled out in front of me on a wet road at 60+ and though it was a pucker moment for sure the brakes (and Pilot Powers) were phenomenal. No locking, no sliding, no drama. I've never really minded the wet before but my wet riding confidence level on this bike is  much higher than anything else I've ridden in the wet.
I actually believe this article was written about the 05/06 as they mention the undertail exhaust and having less violent tank slap than the previous 636. Also the 300mm brakes that were mentioned were 05/06 while the 03/04 sported 280mm.
It's kind of funny knowing what we know now about the direction supersports went as far as ergonomics and reading this article. "Cramped riding position and track focused performance may prove too inflexible for the road."

P.S. - That picture is the color scheme I think I've finally decided on. This week anyway.


« Last Edit: November 18, 2013, 10:50:19 am by IanC »
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Offline Deuce

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #38 on: November 18, 2013, 03:38:54 pm »
I like kawi green.   :21
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Offline Chris

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Re: 2003 Kawasaki ZX6R - WHAT COLOUR?
« Reply #39 on: November 18, 2013, 03:40:59 pm »
Ian,

As you can see from the gallery on the road test web page the bikes were available (in Britain anyway) in black, blue, green and red.  I think the two best looking paint schemes are the black or green.

Dad
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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #40 on: November 18, 2013, 03:50:35 pm »
They were also available is silver:

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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #41 on: November 18, 2013, 06:22:40 pm »
I wonder which countries got which colour schemes?
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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #42 on: December 26, 2013, 11:25:30 pm »
For Christmas my sister and brother in law got me an HID kit for the Kwak. These were sorely needed.  Riding this bike at night, especially with a pretty bad  astigmatism, it's frankly terrifying.  A previous PO did the spray on tint thing to the headlights to make matters worse. 

Here's my low beam before:


And high beam:


One HID in:


HID low beam:


And high beam:


I'll be wet sanding the tint off and polishing the lenses next.
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Offline emd513

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Re:
« Reply #43 on: December 27, 2013, 02:05:45 am »
Nice

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Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #44 on: December 27, 2013, 02:11:51 am »
looking much safer Ian !!! :21
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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #45 on: December 27, 2013, 03:28:12 am »
It was a lucky day for that little Kwacker when you bought it.
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Offline Deuce

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #46 on: December 27, 2013, 04:09:23 am »
It was a lucky day for that little Kwacker when you bought it.

Agreed!  :21
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Offline suzukibandit03

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #47 on: December 27, 2013, 10:27:19 am »
I might have to try them headlights on my Bandit my astigmatism has been bad for years.
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Offline Bobert

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #48 on: December 27, 2013, 08:42:50 pm »
That really makes a big difference. Great gift :)


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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #49 on: December 29, 2013, 12:27:12 pm »
Wet sanded and polished the headlight lenses.



I couldn't find anywhere that I wanted to permanently mount the ballasts. They fit really well in between the turn signal holes and cooling ducts on the lower fairings but I obviously need to take those off from time to time. My solution was really strong Velcro. 

I also put some dielectric grease in the connections,  swapped the headlight fuse to a 20A per their recommendation and tracked down a loose connection to the headlights in my factory harness that was giving me fits.
I haven't had a chance to ride it after dark yet but I'm looking forward to it.
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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #50 on: December 29, 2013, 01:43:07 pm »
Looks good son.  I think the velcro will work just fine.  If not, then perhaps a zip tie to a fairing bracket with a cushion between the bracket and the ballast.
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Offline emd513

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Re:
« Reply #51 on: December 29, 2013, 06:23:42 pm »
My ballast are zipped tied to my wiring harness. There's no where that I could find either for a permanent location, and with my luck on them going out it's easier just to replace the ties. Glad I read this though I have forgot about the fuse needing to be bigger. I'm still running my 10amp. Guess that'd getting changed tomorrow.lol looks good  Ian. Keep it up

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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #52 on: December 30, 2013, 06:58:31 pm »
Finished product.



Next up is tires and a valve job.
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Offline gotgixers

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #53 on: December 31, 2013, 06:10:46 am »
Looking Good  :21  :21
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Offline IanC

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #54 on: January 02, 2014, 02:09:58 pm »
Mmmmm.....

Right now places are only taking pre orders on these as they aren't available yet. I feel so special.  Rep told me this is the only set in the Southeast.  I'll make a post and review them after I get them on.

Need to pick up some wheel bearings and replace them while I have the wheels off.  May also pick up some aluminum 90 degree valve stems to make checking pressure easier.
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Offline Chris

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #55 on: January 02, 2014, 04:11:04 pm »
You're going to love those.  The tyre tread looks funny but the way the Road 3s work in the rain is magic.  I would expect the same from the 4s.
 
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Offline 68gts

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #56 on: January 08, 2014, 07:19:30 pm »
Great write up on your project. I only see one thing that looks out of place. The freakishly long can on the Scorpion pipe just looks to big in the bike to me. Nice work.
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Offline IanC

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Re:
« Reply #57 on: January 08, 2014, 09:21:04 pm »
The can will be replaced.  It's been crushed a bit at the bracket. I don't think it hinders performance and it's hard to see but I don't need much of an excuse to ditch the ugly scorpion.
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Offline drag00nlover

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Re: Re: 2003 Kawasaki ZX6R resurrection.
« Reply #58 on: January 09, 2014, 03:31:10 am »
Whistles at ian and mumbles something about a carbon fiber yoshi r77 with midpipe just laying in storage the just might fit it........

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Offline IanC

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Re: 2003 Kawasaki ZX6R resurrection.
« Reply #59 on: January 09, 2014, 08:47:10 am »
I'd definitely be interested in seeing if it would fit James.
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