636 Swap complete...my experience

[masalma]

So far I have ordered

05-06 Fender
05-06 Axle
05-06 Forks
03-04 Rear Shock

swap into a 03 Z1000

two spacers?
5. '00-'02 Zx600 wheel spacers; Kawi part #92152-1251 (local Kawi dealer)

And 05-06 caliber? or would the stock once fit? rotors?

and what other parts would I need?

Thanx guy, I went through the thread but too much info

Nas

[Throttle_monkey]

Your stock rotors will fit. You need calipers from an 03-up zx6, zx10 calipers will work, I picked up 05 zx10 calipers.

[Throttle_monkey]

You will also need longer brake lines

[masalma]

Originally Posted by Throttle_monkey

You will also need longer brake lines

would I need this too?
7. 10mm x 1.25 pitch x 70mm bolts for calipers

[Russ]

No - you only need the longer bolts with the 03-04 ZX6 front-end as the older 636 has smaller disks.

The standard 05 ZX6 caliper bolts will be fine.

[masalma]

So far I have gathered all the parts for the swap

05-06 Fender
05-06 Axle
05-06 Forks
05-06 caliber
00-02 Zx600 wheel spacers; Kawi part #92152-1251 (local Kawi dealer)
00 gsxr 600 Master Cylinder (get to use my brand new pazzo levers)

so all I need now is the brake lines

2000 Suzuki GSXR 600 Master Cylinder
2005 Kawi ZX6r 636 Calipers

I would want two lines from the MC at 32 and 34 inches lengths.

was hoping to have them in kawi green with black bolts.

I contact a few shops that custom make them and they were inquiring about the angles of the banjos. Any clues?

Also some shops wanted to know the size of the bolts, I tried looking up online but no luck. Suggestions are appreciated. Thank you,

Nas

[Jason 306]

Originally Posted by masalma

So far I have gathered all the parts for the swap

05-06 Fender
05-06 Axle
05-06 Forks
05-06 caliber
00-02 Zx600 wheel spacers; Kawi part #92152-1251 (local Kawi dealer)
00 gsxr 600 Master Cylinder (get to use my brand new pazzo levers)

so all I need now is the brake lines

2000 Suzuki GSXR 600 Master Cylinder
2005 Kawi ZX6r 636 Calipers

I would want two lines from the MC at 32 and 34 inches lengths.

was hoping to have them in kawi green with black bolts.

I contact a few shops that custom make them and they were inquiring about the angles of the banjos. Any clues?

Also some shops wanted to know the size of the bolts, I tried looking up online but no luck. Suggestions are appreciated. Thank you,

Nas

You want to get them pretty straight, I got mine at 10* but could of got them straigh if I wanted. Your lengths sound dead on, I screwed up and order mine at 33" and 29"....the 29 works but is just a bit short when I raise up on the forks....is on my to do list

Also be warned that if your master cylinder is off a 600, it should have a fine thread pitch rather than a course.

[Throttle_monkey]

Masalma- I ordered my lines from spiegler USA. They ship to Canada, I'm in Edmonton. They have different colors too..... I'm just waiting for them to get here.

I'm doing the same upgrade. With the 05 forks, you will want to run them 30mm above the top clamp as they are quite a bit longer. If you run them flush your handling will change.

Under the general z forum there's a thread called "got my rims back". On the second page you can see my bike with the new forks and how they're raised in the clamps.

[cbabe001]

Has anyone made this work with 2003 636 forks and a wheel form a 2005 636? The axle from the 2003 is much too large for the wheel bearings. Will the axle from the 2005 fit the 2003 forks?

[masalma]

I am ordered a set of 05-06 ZX6R EBC HH brake pads, but was wondering is there a difference between ZX6R, 636 ZX636 ? or are they all the same bike?

also picked up a 04-05 ZX10 rear rotor, any interchangeable rotors for the front? that would work with the swap.

[Maxz1000]

Hi All,

I did my suspension swap a few years ago and I am now looking into the sag... I think I need to upgrade the springs as I get about 40mm with the preload nearly all the way. Looking at the various threads I note the RS117 has utalised a 1.0 kg spring. Can anyone else share what they have used.

I have the forks from a 636 2006 model in Silver, so I guess these are 'C' model forks. I also intend the remove the standard spring from the Z1000 rear shock and fit this to the 636 rear shock I have.

For information, I am 85kgs

[Rembrant]

Hi folks,

Can anybody tell me if the '05/'06 rear shock assembly is a direct swap in on the '03-'06 Z1000?

I've read this entire thread end to end a couple times, and it looks like everybody usually uses the '03/'04 rear shock assembly, even if they use the '05/'06 front end parts.

Any light you could shed on this would be great. Thanks.

[atschach]

I am stoked, found a guy who is selling me his 03 forks, axil, and calipers all for $100. This is gonna end up being cheaper than I thought

[atschach]

Well I finishled the swap. I did it by myself and it took around 5 hours or so. I still have a little bit of air in the brake lines I will need to keep working out. Would have helped to have an extra hand doing it, but I guess you can say that about any job. Now I will just need to tune the suspesion a little bit. Thanks for all the into throughout this thread, made doing this a piece of cake.

[Jason 306]

Originally Posted by atschach

Well I finishled the swap. I did it by myself and it took around 5 hours or so. I still have a little bit of air in the brake lines I will need to keep working out. Would have helped to have an extra hand doing it, but I guess you can say that about any job. Now I will just need to tune the suspesion a little bit. Thanks for all the into throughout this thread, made doing this a piece of cake.

Good to hear. All the adjustability aside, the radial forks on the front make the bike look so much better and sportier