TheSloMoShow's Build Thread v.2 - ZX6R Forum
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post #1 of 28 Old 02-15-2015, 09:47 PM Thread Starter
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TheSloMoShow's Build Thread v.2

We'll, I'm at it again...funny how a stint of cold weather and boredom gets the gears turning and the bike into a bunch of pieces This is my second go at tearing the bike apart, the first being last summer when I first bought it from a friend. At that time, it wasn't cared for and looked like crud. Overheated and it didn't feel as powerful as what I remember a 636 feeling like. I had been wanting a project bike for quite some time, and given the challenge, thought this be the perfect one. My initial intentions were to get it running healthy, and add some flavor since I really couldn't stand the original white/silver color scheme. For those who want to catch up, I have the link below to the original thread I posted just after I first finished v.1 and headed out on the maiden voyage to MotoGP Indy.

TheSloMoShow's Build v.1

Round 2 is my desire to increase the aesthetic appeal, run some tests to validate the engine's working order and finetune the ergo's since last summer I really couldn't make it much longer than an hour or two without needing an extensive break. Unfortunately, this second round has taken much longer due to an unexpected snowboarding accident resulting in a broken collarbone (and thus a month and a half away from the bike ). But I'm nearly at the finish line.

I envision a Round 3, where I can tear the engine apart and rebuild with performance in mind but this I don't want to do to the engine I currently have as I may not finish before riding time and spring hits. Thus, I'll most likely try and pickup a spare engine to work on and tear apart in the interim instead. But these are just plans, no need to take action on this just yet...

To gauge the amount of work I have to do this time around, and know what I'm getting myself into I wanted to run some tests first. Mostly for peace of mind, but also to see how an engine such as this can hold up after 30k miles. So first up is the compression test. All were within 7 psi of each other and within spec. No immediate danger.


Since I just adjusted the valves last summer I figure that a leakdown test would prove my good work unless of course the head gasket is starting to go. Surprisingly enough, all 4 cylinders were around 4% leakage give or take 1-2% due to gauge inaccuracies. Thankfully, given the success of both of these tests I knew I had a much easier route to go (versus possibly tearing the engine apart after all because compression etc was out of whack).


Since the leakdown test required draining the oil, I also emptied the coolant and bled the brakes. With the bike empty, I started to work on removing the covers since 1.) I have a new clutch to put in and 2.) I wanted to repaint the covers black to match the frame.

Clutch & timing cover gone. Clutch fibers removed.


Stator and water pump cover removed.


With all the covers gone, I laid down the initial layer of engine enamel but if you are familiar with my first v.1 build thread you know the issues I have run into with paint. For whatever reason, these first few layers on engine enamel had wrinkled up on me (quite possibly there was acrylic laid down at some point that I didn't know about, and the lacquer I laid down after caused it to wrinkle?) Either way, I wasn't going to waste my time trying to fix the issue so I let it dry overnight and started anew the next morning.

Covers sanded down, and primed and then painted once again.


Thank the Lord they finally turned out like I wanted (my patience run thinner and thinner everytime I go to paint something lol).

Newly painted stator cover and water pump cover.


EBC SRC Clutch pack installed just before covers were put back on.


Newly painted timing cover and clutch cover.


The previous owner had neglected to take care of his chain, and one day while riding on the highway had his chain break and snap forward breaking the front half of the sprocket cover. Thus, a whole bunch of gunk has always built up on the backside of my starter and anywhere within that general vicinity. I don't know why I didn' choose to do this sooner, but I went ahead and bought a new cover off eBay for $15 and painted it in the same manner as the rest of the covers.


I bolted all the covers back on, filled the bike up with fresh fluids and proceeded to the next step. And trust me when I say this, this is by far the most crucial one for my bike since I swear my TB's have been off since I first rebuilt it last summer. I've had a couple issues with the bike stalling as I quickly let off the throttle and come to a stop, and also notice that it's not quite as reactive as what my previous 600 was or even my current R1.

I only got a picture of after the job was done, but long story short my cylinder 3 was barely creating anything similar to a vacuum. It was completely, absent. I eventually got all 4 back to the same level, gave the throttle a few quick snaps to make sure the changes stuck and then shut her back off.


With the TB sync out of the way, I was able to move on to what I had been looking forward to for quite some time. I'm a bit of a heavier rider than what I believe my suspension is set up for (unless everything is set to minimal compression and rebound but that make for a rough rough ride). I wanted to overhaul the forks originally because the previous rider was known to wheelie quite frequently and after 30k miles I really can't imagine the oil and dust seals performing to their OEM expectations anymore. I also decided to upgrade the fork springs and going with a 1.0k/mm set which will help quite a bit more.

Front wheel gone, forks ready to be removed.


Fork disassembly area. I gathered some helpful tidbits off a YouTube video from a fellow member who had some good ideas about creating a DIY spring compressor and few other tools.


Both forks completely disassembled and drained.


With the housing and leg separated, I was persuaded to paint the caliper mounts as well since these are really the last remaining parts on the bike (besides the block and head obviously) that aren't already black. Plus, they were pretty dinged up and they needed a makeover.

I originally plastidipped the mounts, along with the top yoke and clip ons.



It didn't take me long to realize though that the look wasn't what I was going for so I ripped the plastidip off the caliper mounts (left it on the other parts) and quickly went through sanding, and painting the mounts with engine enamel.

Looking good...


Let the legs dry overnight, and then gathered myself to finally get the new springs put back in. Of all the stuff I've done to my bike, swapping these springs was a bitch. Honestly, I don't know why but I found this to be the biggest pain in the ass. Of course with practice makes perfect, but exchanging these the first time around certainly taught me some patience.

New Race Tech Springs


My DIY jig from which I got the idea on YouTube. It works pretty well ,and saves some doll hairs versus buying an actual spring compressor.


All assembled and ready to go back on.


With the front wheel off, I decided to take the opportunity to replace the front wheel bearings. I noticed that I was starting to get some resistance, felt the old bearings were at the end of their life.


Front forks back on.

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post #2 of 28 Old 02-15-2015, 09:47 PM Thread Starter
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I'm not sure how this is just now getting attended to, but the smog block offs are finally installed ha.


New ProGrips thrown on, they feel great already!


I had some free time so I plastidipped my stand red (I'm noticing alot of my possessions are turning red lately...)


The only remaining items I have left to tackle on this build round 2 are:

1.) Install new fairings. I ordered a custom set from Auctmarts about a month ago and they should be here this Friday. I'll have a pretty good review and pics up shortly after I get to inspect them, but I'm really pumped since, well, they're red too

2.) Get my custom seat wrapped. I bought some ultragel online, and have already started shaving the original seat foam to allow the gel insert to fit. I'm awaiting the arrival of the fairings though, so I can order the proper vinyl wrap color to match the fairings.

Seat shaved, gel insert within to get an idea of what I'm attempting here.


3.) Sand down the fuel tank, and rear seat cowl and paint to match the fairings. I'm not sure just yet either how or what color I want to paint them, so it will depend on how the fairings look once I fit them on this upcoming weekend.

Maybe....4) I really wanted to get the wheels powder coated/painted this time around but I didn't want to mess with removing the tires just yet. I'll probably wait until about halfway through this upcoming riding season to get new tires, and at that time have them painted a deep gloss black or red. Not sure on the exact details yet...

Well, this is as much as I can possibly type since I need to get my ass up soon to go to work in the morning. Thanks to those have actually read through this entire post -- I will have more to follow up with once the fairings arrive this Friday/weekend, and hopefully have the bike done within the next 2 or 3 weekends
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post #3 of 28 Old 02-16-2015, 05:51 AM
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This is awesome


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post #4 of 28 Old 02-16-2015, 09:49 AM
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Looking really good! I am impressed by your attention to detail and patience. I just hope that paint holds up...
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post #5 of 28 Old 02-16-2015, 10:07 AM Thread Starter
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Looking really good! I am impressed by your attention to detail and patience. I just hope that paint holds up...
Eh, I hope so too. It should be able to withstand up to 500F and oil/gas. If it does end up failing I can always rip the covers off again and have then powdercoated. Only problem there is the clutch cover...not sure how I would go about getting that done because of the glass view window.

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post #6 of 28 Old 02-22-2015, 11:04 AM Thread Starter
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AuctMart Fairings Arrive

I'm a bit surprised -- the fairings shipped out only 4 days ago from Hong Kong and they were at my door yesterday despite the foot of snow Columbus, OH just got. But no better time to tear into the package and get the fairings installed than a day where I'm snowed in anyway

So into the review we shall go. If you are familiar with my V.1 Build TheSloMoShow's Build Thread V.1 then you'll know that I ditched the fairings originally on the bike when I bought it for some unpainted fairings from Delkevic. My intention was to create/finish everything on the bike myself that I could, so I bought them unpainted to give myself the opportunity to improve on spray gun skills. Unfortunately, of all things I've done mechanically to both of my bikes, painting with a spray gun is by far the hardest. Maybe I'm just spray gun illiterate, idk, but it was very hard getting the conditions right to paint in and also to have a calm back and forth motion to get an even coat every time. Nevertheless, I finished the fairings in time to get my ass to MotoGP in Indy but they weren't perfect. Quite a bit of orange peel (which bothers me the most), and a few runs here and there. The side fairings and tank were plagued the most by this issue. So after a season of riding with them, I felt it was time to finally get a set that is painted correctly. Of course, there is always the option to buy OEM fairings but I had a few issues with this. I wasn't wanting to go back to the OEM fairings style -- I wanted something custom. Of course I could still do this with OEM fairings, but it would then cost me twice as much more. And that brings me to my second point, I don't have enough $$$ to buy OEM fairings in the first place .

Aftermarket soon came into the picture. To make a long story short, I honed in on AuctMarts as the manufacturer since they had the best reviews for the price (only ~ $500.00 shipped). I had searched around their website for a week or so, found decals and other colors they were using on different bike models fairing sets and used those to create my own. I sent this concept design to Auctmarts, and they approved at no additional cost. They sent me a revised sketch email to confirm the design and soon thereafter it was in the works. Email communication was great -- being it that were in the U.S.A. responses only come between roughly 22:00-06:00est, but it was always a response within 24 hours. It took a little over 2 weeks since I sent the order in until the fairings were done. They prepared the shipment the following day and it was sent out the night after. I received the shipment in 4 days.

To give you an idea of what size pkg to receive, below are the two boxes they came in. The right and left hand side fairings came by themselves in the flatter box while all others were packaged in the bottom box. There was enough padding/Styrofoam wrapping in each box to last a life time. Each piece is wrapped in a few layers from top to bottom, side to side, and even more so at each corner to prevent scrapes/nicks. (Don't worry about the electrical tape, I did that after I had repacked all of my old fairings back into these two boxes to save space in the garage).



It didn't take long though for me to unravel each box's contents and get everything laid out. The solo seat cowl was not included in the deal from Auctmart's, this was my own that I threw in the picture. Every kit for right now comes with a free fairing bolt kit -- comes in hand big time because a lot of screws/bushings/spacers were either lost or broken upon me taking off the last set. Plus, it's always nice to have something new.



My first impression, in the most honest opinion I can give the forum, was WOW The quality is great, the paint is great, they aren't cheap plastic that you find in the toy store and there wasn't a single blemish/error. Of course they aren't perfect, but we'll get to that.

[Right Hand Side Fairing]
The right and left hand side fairings were much better than I expected. The paint (base & clear) covers the entire fairing, and all of the drilled holes/slots. There is no sign of a rushed paintjob, or half-assing on Auctmart's part. You can see the underside isn't too pretty, and there is quite a bit of overspray but this is completely hidden once they are bolted on (and also by the heatwrap you would then put on too). Paint is silky smooth...


[Nose Fairing]
I was a little worried that the lines on the nose fairing wouldn't be straight or parallell to each other, but I was proven wrong. Looks good, of course "TheDoctor" decal on the LHS could be a bit straighter but nothing that really worries me.


[Tail Fairing]
I ws a bit cautious to see if the paint had reached all edges/area of the underside since there is some space that I feel usually gets missed in a typical paintjob if not done correctly. You can see as with all of the other fairings, the paint reaches all edges, and does not thin out anywhere on the fairing.


[Front Hugger]
No issues here, quality in line with the previous fairings...


[The Rest]
I was a little bugged out by the giant imprint left on the rear hugger from where the mould was filled, but once the hugger is placed on the bike you can't see it. Everything else, is unpainted but looks great. No defects or structural deformities.



I had asked that they use a specific red on this paint job, that was dark but when shone in the light had a bit of shine and orange to it. In some of the above pictures you can see it, really nice quality paint and I was pleased that Auctmarts could meet the request. I really wanted red on the bike, but did not want int to detract from all of the parts that I have had painted black and this darker red really helps keep it 'in line'.

After inspecting each fairing for any incongruities, I was obviously still worried a tad about fitment. Would I have to break my back to get some fairings to fit into place, would I have to drill out some holes to enlarge? Actually, no. Everything fit fine -- without a damn hitch. I couldn't believe it. Even the set that I bought from Delkevic had a harder time fitting than these did.

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post #7 of 28 Old 02-22-2015, 11:20 AM Thread Starter
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Her Clothes are Back On...

And finally, a few pictures with everything fitted back to the bike.

All in all, I'm pumped -- I think these turned out absolutely friggin' great and I can't imagine a better deal for what they cost. Of course, OEM will still hold to be a better quality being it that they are more durable, quite better paint job and better flex but I can only imagine a few instances where this comes in to play. Either when you crash, or when you install/uninstall your fairings to work on the bike. If you can make sure to handle the fairings with ease in doing so, then I don't see why you wouldn't go aftermarket over OEM, but this is just MHO. For each his own...




Now, again, only remaining items I have left to tackle on this build round 2 are:

1.) Finish wrapping the seat. Now that I finally have the fairings and I know the true color of the red, I can buy the vinyl I need to complete my seat and also can complete getting a proper color matched tank and cowl.

2.) I was originally going to re-paint my tank and cowl, but think it might be easier to find a used black tank and/or cowl off someone than re-painting myself, soooooo if you have one definitely PM me. I'd be interested in most offers.

3.) Thanks to some advice from other members, I think an 05/06 swinger transplant is due. Haven't done too much digging into it as far as finding parts, but i know what's needed. This may happen later in the season as it isn't necessary to get me going just yet....

4.) I'm looking at some hardware to help mount/dismount my own tires. Once I can get this in house, I'll be powedercoating the rims.
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post #8 of 28 Old 02-22-2015, 11:22 AM
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Great review. Thanks for taking the time to write it up!

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post #9 of 28 Old 02-22-2015, 05:38 PM
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Looks good man. Did the cat come with it?
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post #10 of 28 Old 02-22-2015, 06:00 PM Thread Starter
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Looks good man. Did the cat come with it?
Lol, you would think so. The cat wanted to make everything into a scratching post, wouldn't leave me alone.

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post #11 of 28 Old 02-22-2015, 06:30 PM
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Damn! Looks like you did a lot of good work on this thing man

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post #12 of 28 Old 02-22-2015, 06:32 PM Thread Starter
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Damn! Looks like you did a lot of good work on this thing man
Appreciate it brother

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post #13 of 28 Old 03-01-2015, 07:23 PM
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That's crazy. Your v1 was insane. I'm pretty new to bikes (this will the beginning of my 3rd season) but have worked on cars and I have no idea if I'd be able to put a bike together again after taking it apart to the extent you did.

Awesome stuff man!

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post #14 of 28 Old 03-01-2015, 07:32 PM Thread Starter
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That's crazy. Your v1 was insane. I'm pretty new to bikes (this will the beginning of my 3rd season) but have worked on cars and I have no idea if I'd be able to put a bike together again after taking it apart to the extent you did.

Awesome stuff man!
Then you haven't caught the addiction yet lol! I said the same thing a long time ago until I found that doing this type of work puts myself at ease, forget about everything else and all of life's stress. You'd be surprised what you're able to get done when your calm and concentrated. Haven't stopped since

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post #15 of 28 Old 03-12-2015, 07:44 PM
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Was the fit 100%? this is the only thing making me cautious in buying aftermarket fairings... i have now got my 2nd set from an ebay seller... 1st set i managed (just) to get all the bolts on... this time around on a fresh set ive got 2 bolts missing on eother side of the frong fairing -.-.

They arent shaped even close to original fairings.. Do yours fit perfect? Cant wait to get my J1 in perfect condition!
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