636 Front End Swap Progress Thread

Jtpaintball70 · 10-09-2007, 09:46 AM

Gonna be using this to have a progress log of my project.
Said project is swapping in a 2003 ZX-6R front end into my 650R, mounting a Vortex fairing bracket and a full set of Catalyst fairings (including tail), adding Valter Moto Rearsets, installing a Hagon rear shock, and putting on my blue wheel stripes.
So, here we go.

423.8 mile round trip to pick up the forks

Still need a few bolts, a front fender, top triple clamp, and to decide whether I wanna use my 650R master cylinder or try and see if the Pazzo works on teh 636 one. Although I found several places I can buy just the brake side Pazzo for the 636 master cylinder, since I would like to stick with using that one.

nater · 10-09-2007, 10:02 AM

In case you had not thought of it, it would be a good ideal to use some Bel Ray waterproof grease to grease up your steering head bearings while you have everything apart.

Jtpaintball70 · 10-09-2007, 10:09 AM

Quote:

Originally Posted by nater

In case you had not thought of it, it would be a good ideal to use some Bel Ray waterproof grease to grease up your steering head bearings while you have everything apart.

Got some sitting at my appt actually

Currently the forks are at work where the techs are doing a fork rebuild for me. New oil seals etc. Getting a set of SS lines as well, since I love the ones already on my 650R.

Jtpaintball70 · 10-28-2007, 08:13 PM

Add to the list:
Installing an 05 636 gauge cluster

Jtpaintball70 · 11-07-2007, 10:49 PM

Woodcraft rearsets are installed! Need to notch a little bit in the lower to accommodate for GP shifting

l3uddha · 11-07-2007, 11:00 PM

are those forks the same length? a suspension shop should be able to machine a top triple for you. they can check the new geometry too and adjust if necessary.

Jtpaintball70 · 11-08-2007, 08:43 AM

Quote:

Originally Posted by l3uddha

are those forks the same length? a suspension shop should be able to machine a top triple for you. they can check the new geometry too and adjust if necessary.

I believe they are the same length. And I managed to pick up a top triple at work from a salvage bike for cheap. One thing about the 03-04 636 front end is that it's a direct bolt on for a 650R

l3uddha · 11-08-2007, 09:48 AM

Quote:

Originally Posted by Jtpaintball70

I believe they are the same length. And I managed to pick up a top triple at work from a salvage bike for cheap. One thing about the 03-04 636 front end is that it's a direct bolt on for a 650R

those internet writeups can be your worst enemy. "direct" is never direct. dont ask me how I know....

the upgrade has a lot of potential, but you should definitely take it to a suspension guy and have him check the geometry for you... & while you're there get the forks revalved and sprung for your weight...

that might start getting expensive, but in all seriousness you should at least get the geometry set for that front end, which shouldnt be that expensive. even if they bolt in easily they are nothing alike. different forks & springs for different applications. it's just a guess, but I'm thinking that even if, by some slim chance, they are the same in length however you unaccurately decide to measure them, the springs in the 636 are probably stiffer and will rake out your front.

point is, you get the impression that it'll be a big improvement, when it's actually working against you & you dont even know it. I'm sure you'll go for a ride on it, it'll feel different, & you'll be like "whatever this is great!"... but you dont even know... wrong part for the wrong application = dangerous.
though your new part correctly made to fit = friggin sweet.

you work at a bike shop or something? i noticed u said they were rebuilding it. the rebuild for the forks is good, but the whole bike needs to be checked by a suspension guru, which you wont find at a normal bike shop.

l3uddha · 11-08-2007, 09:59 AM

stick with the 636 master.

Jtpaintball70 · 11-08-2007, 10:06 AM

Quote:

Originally Posted by l3uddha

those internet writeups can be your worst enemy. "direct" is never direct. dont ask me how I know....

the upgrade has a lot of potential, but you should definitely take it to a suspension guy and have him check the geometry for you... & while you're there get the forks revalved and sprung for your weight...

that might start getting expensive, but in all seriousness you should at least get the geometry set for that front end, which shouldnt be that expensive. even if they bolt in easily they are nothing alike. different forks & springs for different applications. it's just a guess, but I'm thinking that even if, by some slim chance, they are the same in length however you unaccurately decide to measure them, the springs in the 636 are probably stiffer and will rake out your front.

point is, you get the impression that it'll be a big improvement, when it's actually working against you & you dont even know it. I'm sure you'll go for a ride on it, it'll feel different, & you'll be like "whatever this is great!"... but you dont even know... wrong part for the wrong application = dangerous.
though your new part correctly made to fit = friggin sweet.

you work at a bike shop or something? i noticed u said they were rebuilding it. the rebuild for the forks is good, but the whole bike needs to be checked by a suspension guru, which you wont find at a normal bike shop.

I will take it to a suspension guy. Sicne I'm also swapping rear suspension to a Hagon shock built for my weight and height and bike, I figure I can get the most out of it that way

And yea, I do work for a dealership. We have 2 racers working there, one former AMA roadracer, and one state desert race champion. The roadracer is my manager (parts), and he's already offered his help if it's needed.