The Evolution of my SexDirtySex!

Ming · 09-15-2009, 09:59 AM

Story:
I bought my latest bike last month, 2003 Kawasaki Ninja ZX-6R aka 636, with almost 16,000 HARD miles on it, down on both sides, blown fork seals, etc. Besides oil changes and plugs (which probably was only done right before I got the bike), the bike looks like it was never maintained. I used that to my advantage to get the bike for a pretty good price, also knowing what I wanted to do, and what I'd be getting into. Here it was, the perfect chassis to build my stunt piece!

The evolution of the 636 started with basic maintenance. The bike ran like crap when I bought it, so I needed to do some work. Here we go!

This is the dirty whore after I bathed her: (notice only 1 frame slider)

So first things first. Installed New Shogun frame sliders. Also relocated the PCIII.

Now, to get her purring. Maintenance involved swapping tires to Pilot Powers, straightening the gas tank, adjusting the CCT, degreasing the engine, fix some terrible wiring, swapping to water wetter, changing the oil, cleaning and lubing chain, bleeding the brakes, and replacing the bearings and seals in the rear wheel. (All complete, not all on the same day, and didn't want to bore you with maintenance pics)

The next mod is mainly for stunting. This is the best mod EVER on an 03-04 636. The swap to 05-08 forks require the forks, 05-08 front brake rotors, and 05-08 front fender. (I chose to use the 07-08 showa forks because of the stiffer internals, and they were silver instead of gold, got a color matched 07 front fender, and used 06 rotors which bumped me up from a 280mm rotor to a 300mm wave rotor.) The stock KYB forks from the 03-04 636's are notorious for snapping when pulling long/fast stoppies, since this will be my future stunt piece I chose to swap em rather than DIE. Everyones seen the pic of the blue 636 and if you haven't here it is! (fork swap are pics after failed stoppie)

Next I needed more stopping power. Even after bleeding the line on the 03-04 636 brakes, they were spongy as hell. I decided to upgrade to Tokico calipers, lines, and Nissan lever, and brake master off of a 06 ZX-10R. (Better adjustments up top, with a master bleeder, also got rid of the gold. Not as straight forward as the fork swap, the brake reservoir needs to be relocated, and the throttle cables need to be moved, but still something that can easily be done in your garage)
(old setup)

(new setup)

Last but not least, bumped up from the stock 40t rear sprocket to a 43t rear sprocket. Not a drastic change, but will be nice out at MMP in October, and will bump up to a 52t-60t this winter. (oh yeah, put on some rear spool sliders as well)

This is the transformation so far, stay tuned as the 636 gets stunted out!

Matt · 09-15-2009, 11:22 AM

I freakin love bikes!!!!

Pretty soon we should be done workin on them and ready to ride again

Bikejunky · 09-15-2009, 01:03 PM

Damn Ming you've put some time into that beast, but I still don't know about the the post title, haha.

Hozhead · 09-15-2009, 07:11 PM

Looking great, Ming! Keep up the good wrenching.

shaner · 09-15-2009, 08:57 PM

Haha. It took me all night to get the whole SexDirtySex thing! Sometimes I can be wee todded. Nice progress though Ming. I know what it's like to tear a whole bike down like that.

LazyJ · 09-16-2009, 10:32 AM

I think your license plate should say....pnktco

HaVocX · 09-16-2009, 11:07 AM

good work bro. its always good to get to know yer bike. every bike i have boughten has needed some shinin up. thats how you get the good deals.

keep postin pics.
is that really the same bike in that pic??

micko24 · 09-16-2009, 02:34 PM

nice work Ming, did you do that on your own, I would like to learn to do all the fork work stuff. again good work.

HaVocX · 09-16-2009, 04:14 PM

you should get some lines for those new calipers! really get that bite. i like how your looking in the brake direction tho. i want to do that Galfer SS front brake kit. pads, lines, the works.

Hozhead · 09-16-2009, 09:33 PM

Quote:

Originally Posted by lazyj

i think your license plate should say....pnktco

ha ha!!

Ming · 09-17-2009, 03:08 AM

Quote:

Originally Posted by micko24

nice work Ming, did you do that on your own, I would like to learn to do all the fork work stuff. again good work.

yep. all in the garage, with help form some friends. wrenching ain't ###t unless you got some bro's to join you in the fun! That and some 40'z,

that's how the forks, rotors, and shiz got done.

Ming · 09-17-2009, 03:10 AM

Quote:

Originally Posted by HaVocX

good work bro. its always good to get to know yer bike. every bike i have boughten has needed some shinin up. thats how you get the good deals.

keep postin pics.
is that really the same bike in that pic??

Thanks bro.

And yes, the same bike.

Ming · 09-17-2009, 03:12 AM

Quote:

Originally Posted by HaVocX

you should get some lines for those new calipers! really get that bite. i like how your looking in the brake direction tho. i want to do that Galfer SS front brake kit. pads, lines, the works.

I did that set up on my 06 636 before selling it to Nismofreak. I didn't ever get to ride the setup, since it was mainly my track piece at that time. (end of season, and track happy). But I did ride it on the street a few times and it felt solid! Mostly for pully up that back wheel!

Ming · 10-06-2009, 11:49 AM

Newest mod to the bike, Kawi Kleen Air Mod:

This is a modified version of the original Kleen air mod for the 03-04 zx-6r. Originally the Kleen air mod was designed for racers. Their mod was designed with block-off plates to give better throttle control, help eliminate the "kawi tick", supposedly increase hp, and help prevent backfiring. My version is similar but a bit different. Instead of block-offs that only stop the vacuum from the engine head to the air box, this version of the mod eliminates any chance of oil entering the air box. The PCV valve that usually gets removed, gets routed to the crank case, and all openings to the air box gets plugged. Pics are always better than words, so here she is. One of the most useful Stunt Mods.

1. Gotta remove all the Cali emissions junk, PCV valve, and other vacuum lines.

2. Here is the "T" that I used in place of the valve

3. vacuum lines to the throttle body manifold capped

4. Over view pic. Shows the new vacuum line from the PCV to the crank case pretty well. No more oil in the air box!

5. block off all the openings to the air box. Mainly the original vacuum line that went from the crank case to the air box. (some are not pictured)

Tada!

Matt · 10-06-2009, 04:12 PM

Cool mod, but don't you have to do a wheelie first before you get oil in your airbox??

LazyJ · 10-06-2009, 04:13 PM

Quote:

Originally Posted by Matt

Cool mod, but don't you have to do a wheelie first before you get oil in your airbox??

WHAT! no pic of the oil diagram?

Matt · 10-06-2009, 04:17 PM

Quote:

Originally Posted by LazyJ

WHAT! no pic of the oil diagram?

Just hang just one second there! Never say never

LazyJ · 10-06-2009, 04:20 PM

Quote:

Originally Posted by Matt

Just hang just one second there! Never say never

Ming · 10-06-2009, 06:51 PM

Quote:

Originally Posted by Matt

Cool mod, but don't you have to do a wheelie first before you get oil in your airbox??

Quote:

Originally Posted by Matt

Just hang just one second there! Never say never

Ming · 11-07-2009, 07:39 PM

Mmmm... Bike is now set up for some stunt action.
I will wait til I'm better at wheelies before turning it into a lot bike, but here it is. Upgraded to a 50t Vortex rear sprocket, EK 520 SRX chain (114 links). Also threw on a Powers Stuntworks crash cage. Bike is slowly but surely progressing into a full on stunter.

cms1172 · 11-07-2009, 07:50 PM

Is that bike really PINK or does it look pink in the pictures?

Ming · 11-07-2009, 07:52 PM

Quote:

Originally Posted by cms1172

Is that bike really PINK or does it look pink in the pictures?

its less pink than yours, but gets more.

cms1172 · 11-07-2009, 07:54 PM

But mine looks more like an ALIEN. they say its racing RED

katnip · 11-07-2009, 08:38 PM

I like pink

Matt · 11-08-2009, 10:07 AM

Ming · 01-24-2010, 01:27 PM

Flipped the clip-ons, and added a MSR EZ-pull.

Ryan@IdahoSportBikes · 01-24-2010, 09:03 PM

Very nice!!

Matt · 01-26-2010, 09:21 PM

Now it's time to test it!! Muahahahaha

scooterholic · 01-26-2010, 10:41 PM

Nice looking bike, I like what you've done to it.

Ming · 02-21-2010, 09:29 PM

Got some more work done on the dirty.

Got a Polisport headlight, chopped my fairings, relocated my gauges and controls, and now am rollin Stuntfighter.

steven32 · 02-21-2010, 11:10 PM

where did you get that key chain

Ming · 02-23-2010, 12:30 PM

Quote:

Originally Posted by steven32

where did you get that key chain

Jermacide · 02-23-2010, 12:36 PM

well.................it was a nice looking bike

j/k

Ming · 04-19-2010, 10:36 AM

Got me a new round bar!
Hit up NDCustomz for pimp ish!

Since my tail was off, first thing was to relocate my PCIII AGAIN. lol. Also re-ran the wiring for a cleaner look.

And now for the round bar!

Ming · 04-19-2010, 10:22 PM

Got my OMR sub cage today! It's legit!

Ming · 05-05-2010, 01:07 PM

Got my Fti Dual Quad caliper HB setup installed!
Running a 07 CBR1000RR master, 80"in steel braided line, and 2 Nissin calipers from an F4i.

Bike is now completely set up!

Pics:

And just some random pics I took of my stunt piece.

% · 05-05-2010, 02:41 PM

Awesome!!

mxroostin · 05-05-2010, 03:25 PM

George, bike almost looks to nice to stunt...Its come a long way...Congrats on being done...Now whats next?

CBRF2Old · 05-05-2010, 05:03 PM

Quote:

Originally Posted by mxroostin

Congrats on being done...Now whats next?

Ummm, it's done...what would be next?

Bike looks great. Love the dual calipers on the rear!

steven32 · 05-05-2010, 05:33 PM

damn that thing has come a long way. looks great!

09-15-2009, 09:59 AM	#1
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	The Evolution of my SexDirtySex! Story: I bought my latest bike last month, 2003 Kawasaki Ninja ZX-6R aka 636, with almost 16,000 HARD miles on it, down on both sides, blown fork seals, etc. Besides oil changes and plugs (which probably was only done right before I got the bike), the bike looks like it was never maintained. I used that to my advantage to get the bike for a pretty good price, also knowing what I wanted to do, and what I'd be getting into. Here it was, the perfect chassis to build my stunt piece! The evolution of the 636 started with basic maintenance. The bike ran like crap when I bought it, so I needed to do some work. Here we go! This is the dirty whore after I bathed her: (notice only 1 frame slider) So first things first. Installed New Shogun frame sliders. Also relocated the PCIII. Now, to get her purring. Maintenance involved swapping tires to Pilot Powers, straightening the gas tank, adjusting the CCT, degreasing the engine, fix some terrible wiring, swapping to water wetter, changing the oil, cleaning and lubing chain, bleeding the brakes, and replacing the bearings and seals in the rear wheel. (All complete, not all on the same day, and didn't want to bore you with maintenance pics) The next mod is mainly for stunting. This is the best mod EVER on an 03-04 636. The swap to 05-08 forks require the forks, 05-08 front brake rotors, and 05-08 front fender. (I chose to use the 07-08 showa forks because of the stiffer internals, and they were silver instead of gold, got a color matched 07 front fender, and used 06 rotors which bumped me up from a 280mm rotor to a 300mm wave rotor.) The stock KYB forks from the 03-04 636's are notorious for snapping when pulling long/fast stoppies, since this will be my future stunt piece I chose to swap em rather than DIE. Everyones seen the pic of the blue 636 and if you haven't here it is! (fork swap are pics after failed stoppie) Next I needed more stopping power. Even after bleeding the line on the 03-04 636 brakes, they were spongy as hell. I decided to upgrade to Tokico calipers, lines, and Nissan lever, and brake master off of a 06 ZX-10R. (Better adjustments up top, with a master bleeder, also got rid of the gold. Not as straight forward as the fork swap, the brake reservoir needs to be relocated, and the throttle cables need to be moved, but still something that can easily be done in your garage) (old setup) (new setup) Last but not least, bumped up from the stock 40t rear sprocket to a 43t rear sprocket. Not a drastic change, but will be nice out at MMP in October, and will bump up to a 52t-60t this winter. (oh yeah, put on some rear spool sliders as well) This is the transformation so far, stay tuned as the 636 gets stunted out! Last edited by Ming; 09-15-2009 at 10:32 AM.

10-06-2009, 11:49 AM	#14
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	Kleen Air Mod Newest mod to the bike, Kawi Kleen Air Mod: This is a modified version of the original Kleen air mod for the 03-04 zx-6r. Originally the Kleen air mod was designed for racers. Their mod was designed with block-off plates to give better throttle control, help eliminate the "kawi tick", supposedly increase hp, and help prevent backfiring. My version is similar but a bit different. Instead of block-offs that only stop the vacuum from the engine head to the air box, this version of the mod eliminates any chance of oil entering the air box. The PCV valve that usually gets removed, gets routed to the crank case, and all openings to the air box gets plugged. Pics are always better than words, so here she is. One of the most useful Stunt Mods. 1. Gotta remove all the Cali emissions junk, PCV valve, and other vacuum lines. 2. Here is the "T" that I used in place of the valve 3. vacuum lines to the throttle body manifold capped 4. Over view pic. Shows the new vacuum line from the PCV to the crank case pretty well. No more oil in the air box! 5. block off all the openings to the air box. Mainly the original vacuum line that went from the crank case to the air box. (some are not pictured) Tada!

11-07-2009, 07:39 PM	#20
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	Stuntin' Mmmm... Bike is now set up for some stunt action. I will wait til I'm better at wheelies before turning it into a lot bike, but here it is. Upgraded to a 50t Vortex rear sprocket, EK 520 SRX chain (114 links). Also threw on a Powers Stuntworks crash cage. Bike is slowly but surely progressing into a full on stunter.

02-21-2010, 09:29 PM	#30
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	Stuntfighter Got some more work done on the dirty. Got a Polisport headlight, chopped my fairings, relocated my gauges and controls, and now am rollin Stuntfighter.

04-19-2010, 10:22 PM	#35
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	OMR sub cage Got my OMR sub cage today! It's legit!

09-15-2009, 11:22 AM	#2
Matt Enforcer Joined: Jun 2007 From: Boise, Idaho Posts: 1,919 I Ride: 2006 Ninja GSXR 636	I freakin love bikes!!!! Pretty soon we should be done workin on them and ready to ride again

09-15-2009, 01:03 PM	#3
Bikejunky Batman Joined: May 2008 From: Kuna, K-town, The Desert Posts: 849 I Ride: 07 Gixxer 750	Damn Ming you've put some time into that beast, but I still don't know about the the post title, haha.

09-15-2009, 07:11 PM	#4
Hozhead Joined: Feb 2006 From: Price, UT Posts: 6,810 I Ride: Husqvarna SM610	Looking great, Ming! Keep up the good wrenching.

09-15-2009, 08:57 PM	#5
shaner The All Knowing Joined: May 2008 From: The Hood Posts: 3,446 I Ride: ...............	Haha. It took me all night to get the whole SexDirtySex thing! Sometimes I can be wee todded. Nice progress though Ming. I know what it's like to tear a whole bike down like that.

09-16-2009, 10:32 AM	#6
LazyJ The Easter Bunny Joined: May 2007 From: FUQ Posts: 8,069	I think your license plate should say....pnktco

09-16-2009, 11:07 AM	#7
HaVocX That Guy... Joined: Sep 2009 From: Boise Posts: 314 I Ride: 07 600RR Track, 71 Triumph Hardtail, 82 Honda CM400 'Street Trckr'	good work bro. its always good to get to know yer bike. every bike i have boughten has needed some shinin up. thats how you get the good deals. keep postin pics. is that really the same bike in that pic??

09-16-2009, 02:34 PM	#8
micko24 Big Foot Joined: Jul 2007 From: boise Posts: 1,802	nice work Ming, did you do that on your own, I would like to learn to do all the fork work stuff. again good work.

09-16-2009, 04:14 PM	#9
HaVocX That Guy... Joined: Sep 2009 From: Boise Posts: 314 I Ride: 07 600RR Track, 71 Triumph Hardtail, 82 Honda CM400 'Street Trckr'	you should get some lines for those new calipers! really get that bite. i like how your looking in the brake direction tho. i want to do that Galfer SS front brake kit. pads, lines, the works.

10-06-2009, 04:12 PM	#15
Matt Enforcer Joined: Jun 2007 From: Boise, Idaho Posts: 1,919 I Ride: 2006 Ninja GSXR 636	Cool mod, but don't you have to do a wheelie first before you get oil in your airbox??

11-07-2009, 07:50 PM	#21
cms1172 Master Yoda Joined: Jun 2007 From: The Middle of Nowhere? Posts: 2,460 I Ride: Buell 1125CR	Is that bike really PINK or does it look pink in the pictures?

11-07-2009, 07:54 PM	#23
cms1172 Master Yoda Joined: Jun 2007 From: The Middle of Nowhere? Posts: 2,460 I Ride: Buell 1125CR	But mine looks more like an ALIEN. they say its racing RED

11-07-2009, 08:38 PM	#24
katnip Space Monkey Joined: Jul 2008 From: The Gator's Lair Posts: 1,652 I Ride: '06 GSXR 600	I like pink

11-08-2009, 10:07 AM	#25
Matt Enforcer Joined: Jun 2007 From: Boise, Idaho Posts: 1,919 I Ride: 2006 Ninja GSXR 636

01-24-2010, 01:27 PM	#26
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	Flipped the clip-ons, and added a MSR EZ-pull.

01-24-2010, 09:03 PM	#27
Ryan@IdahoSportBikes Dr. Evil Joined: Jun 2006 From: Boise Posts: 3,102 I Ride: R6	Very nice!!

01-26-2010, 09:21 PM	#28
Matt Enforcer Joined: Jun 2007 From: Boise, Idaho Posts: 1,919 I Ride: 2006 Ninja GSXR 636	Now it's time to test it!! Muahahahaha

01-26-2010, 10:41 PM	#29
scooterholic Space Monkey Joined: Oct 2009 From: Nampa, Id Posts: 1,699 I Ride: Suzuki 01 Gsx 600 f, 07 Honda Reflex, 92 Ninja ZX7 (in bike coma) Weedeater one	Nice looking bike, I like what you've done to it.

02-21-2010, 11:10 PM	#31
steven32 Joined: Feb 2010 From: K-Town Posts: 3,018 I Ride: '07 GSXR 600	where did you get that key chain

02-23-2010, 12:36 PM	#33
Jermacide Light Houses Rule Joined: Feb 2010 From: id Posts: 360	well.................it was a nice looking bike j/k

04-19-2010, 10:36 AM	#34
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	Got me a new round bar! Hit up NDCustomz for pimp ish! Since my tail was off, first thing was to relocate my PCIII AGAIN. lol. Also re-ran the wiring for a cleaner look. And now for the round bar!

05-05-2010, 01:07 PM	#36
Ming Keyboard Ninja Joined: May 2008 From: Boise Posts: 1,797 I Ride: a dirt bike with street tires	Got my Fti Dual Quad caliper HB setup installed! Running a 07 CBR1000RR master, 80"in steel braided line, and 2 Nissin calipers from an F4i. Bike is now completely set up! Pics: And just some random pics I took of my stunt piece.

05-05-2010, 02:41 PM	#37
% Wanderer Joined: Jan 2007 From: Caldwell Posts: 27 I Ride: 636	Awesome!!

05-05-2010, 03:25 PM	#38
mxroostin Indiana Jones Joined: Jun 2007 From: Meridian Posts: 1,153 I Ride: CBR 1000 RR	George, bike almost looks to nice to stunt...Its come a long way...Congrats on being done...Now whats next?

05-05-2010, 05:33 PM	#40
steven32 Joined: Feb 2010 From: K-Town Posts: 3,018 I Ride: '07 GSXR 600	damn that thing has come a long way. looks great!

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode