Home Magazine ZX636 03-04 STUNT BIKE BUILD

ZX636 03-04 Stunt Bike Build

#tuning #stunt bike #Bike protection

Our stuntbike project on Kawasaki ZX636. Full preparation and detailed description of each setup and modification.

11 years ago

One of Alexander Andreev's students asked us to prepare a motorcycle based on a Kawasaki ZX6R 03-04 for training, which he could use to get to the riding area by himself (the fairings and lights had to be kept). The ZX6R 03-04 is the most popular bike in the sport thanks to a powerful, reliable engine with smooth power delivery, good steering and spare parts availability. Nevertheless, the bike is old and equipped with a cheap fork, weak brakes and a fragile frame. Preparing such a motorcycle is time-consuming and expensive, but in the end you can get a great stuntbike!

The experience of professional riders shows that a stock engine lasts longest under training and show use. Many do not even change oil. Therefore, we didn't do anything with the engine.

Cage

The motorcycle is equipped with a Stuntex Mad Dog cage made of cold-drawn seamless structural steel with a unique symmetric geometry. The cage has two sliders on each side with polyurethane damping elements. To relieve the front engine mounts, which are very weak on the ZX6R 03-04, brackets are provided. This solution is an alternative to the steel frame, which is much heavier and more expensive. Installing the cage while keeping the fairings takes some time, so watch the video down below to avoid any mistakes.

1/4

2/4

3/4

4/4

Handbrake

The bike is equipped with a handbrake with two radial 4-piston calipers, a 16 mm Brembo master cylinder and an oversized brake disc. This scheme provides a good sensitivity of the doubler and easy braking. In combination with a doubler there is a classic easy-pull clutch lever. Due to the peculiarity of the bracket, we had to change the caliper on the foot brake.

Steering

The motorcycle is equipped with adjustable clip-ons with thick-walled elongated LSL tubes, which allow you to set up any handlebar configuration and make routing and adjusting the cables easier. All the tips of the tubes have minimalistic handlebar weights LSL Flat Caps. The throttle cable had to be routed under the airbox. Thanks to the clip-ons, it was easy to install a compact GPR V4 steering damper. ABM brake fluid reservoirs are neatly hidden behind the clip-on risers thanks to the flexible mount. With the help of the spacer from the LSL handlebar weights, the reservoirs are easy to mount in the clip-on tube.

The left remote fits perfectly on the edge of the cage!

Fork and front brakes

The stock Kayaba fork was replaced with a better Showa fork from the ZX6R 05-06. This also required ZX6R 05-06 brake discs. For a full upgrade of the front brakes, reinforced hoses and a 19 mm Brembo master cylinder were installed. For the stop signal to work, it was necessary to install a double banjo bolt with a sensor. Replacing the fork requires replacing the front fender, but you can keep the stock one on homemade mounts. Fork legs are protected by Dirt Skinz fork socks. During trainings, the fork is compressed for the entire stroke, and the wear of the oil seals increases significantly. Neoprene socks keep dust and water off the fork tubes, which significantly extends the life of the oil seals.

Exhaust

Shortening the muffler and mounting it under the swingarm is the best solution where it does not interfere and is well protected. To fasten the muffler to the footpeg bracket, we needed to unscrew the footpeg mounting bolt. This can be done by heating it with a torch — in this case the thread lock is destroyed.

Fairing stay

The motorcycle owner wanted to leave the plastic and the headlamp, which required the installation of a steel fairing stay. The stay had to be shortened for free placement of the clip-ons. The windscreen is attached with zip ties that will break under load without damaging the plastic.

Pegs

In the front and rear wheels we installed sturdy Stuntex pegs on aluminum bases. Thanks to the aluminum bases and durable axle, the pegs do not bend. The rear right peg is slightly longer to protect the muffler.

Tail

At the end of the subframe there is a minimalistic round bar with a stop signal to ride in the city. There is also an aluminum RSC subcage with adjustable footrests. The stock subframe is strong enough to withstand many hits, so most riders do not reinforce it. In the back seat there is a hole for the foot.

Tank

The tank has a recess and a ledge, and the filler cap is moved forward. The working part of the tank is covered with a material that has good traction.