MFChop's #396 - 2005 ZX6R Race Bike Build - ZX6R Forum
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post #1 of 19 Old 05-05-2015, 11:08 AM Thread Starter
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Arrow MFChop's #396 - 2005 ZX6R Race Bike Build

So Ive never really posted my build on here so Ill piece it together from a previous thread and updated this one to as I go along.

Armour Bodies Race fairings
Bestem Carbon Fiber Fender
K-Tech 25SSK Cartridges
K-Tech 35DDS Pro Rear
ZX-6RR Rear Linkage
BMC Filter
Hamaguchi Ti Exhaust
DynoJet Power Commander 3USB
DynoJet Ignition Module
DynoJet Quick Shifter
STM Slipper Clutch
Factory Pro Shift Star
Shorai Battery
Ivans Servo Eliminator
Ivans Pair Block off plates
Samco Coolant Hoses
AFAM -1 +2 Sprockets
Brembo RCS19 M/C
Nissin Calipers
Spiegler Lines Front and Rear
CL C60 Pads Front RX3 Rear
D.I.D 520 EVR3 chain
1/4 Turn Throttle
Woodcraft Rear sets
Woodcraft Frame sliders
Woodcraft Stator Cover
Woodcraft Crank Case Cover
Woodcraft Clip ons
Woodcraft Toe Guard
Woodcraft Ignition Key Switch Eliminator
434 Racing Levers
434 Racing Ti Race Bolts
Scotts Ohlins Steering damper
NGK CR9E Plugs
Pirelli Diablo Supercorsa 120/170 SC2 f - 180/60 SC1 r



I ll add some more pics shortly

Special thank you to my 2015 Sponsors for all their help this season!!
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post #2 of 19 Old 05-05-2015, 11:13 AM Thread Starter
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post #3 of 19 Old 05-05-2015, 11:17 AM Thread Starter
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post #4 of 19 Old 05-05-2015, 11:17 AM Thread Starter
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post #5 of 19 Old 05-05-2015, 11:23 AM Thread Starter
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post #6 of 19 Old 05-05-2015, 12:35 PM
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What a piece of junk!

:-p

Just kidding. I have seen this bike in person and MFChop is one of the few people that can hold a candle to my OCD'ness.

This thing is a mean machine, looks great, and honestly for the work that is done to the bike it puts out some really good power.
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post #7 of 19 Old 06-01-2015, 02:22 PM
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What do you think of the K-tech suspenders?
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post #8 of 19 Old 06-01-2015, 02:39 PM
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The east coast is doing big things! Nice bike
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post #9 of 19 Old 06-01-2015, 05:29 PM Thread Starter
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Quote:
Originally Posted by greenmeeny View Post
What do you think of the K-tech suspenders?
Love it, they spent a lot on the R&D for their product line. Build quality is superb and they perform flawlessly.

They've become the suspension of choice more and more over the past few years for many race teams

Check out Advance Traction in my sig!
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post #10 of 19 Old 07-18-2015, 03:11 PM Thread Starter
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Finally got some free time back in CT this weekend to install my Factory Pro Shift Star even took some pics....

Install was pretty straight forward, although I had to re do it all because the star wasn't fully indexed. The offset nipple on the shaft was a PITA to align with the stiffer detent spring installed

Stock on left








FAP FAP FAP



Shifts are definitely firmer and more positively engaged, defiantly worth it
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post #11 of 19 Old 07-18-2015, 05:16 PM
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That star and clutch got me way to moist. Those parts look like pure sex.
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post #12 of 19 Old 07-18-2015, 10:37 PM
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The whole bike is amazing quite a rare exhaust I see that one a lot more on the rc 51 first time I ever seen it on the 6r gotta say very impressed with the whole bike I'm thinking of going k tech as well for suspension on my 13 gonna start with the rear shock and go from there
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post #13 of 19 Old 08-04-2015, 07:35 AM Thread Starter
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So a bit of an update, reposted from another thread....

During second practice; entering T3 I took a downshift and heard some chatter from the transmission as the gear wouldn't engage. I tried to up shift still nothing, so a bailed into the T3-T10 split ending my practice. I had had this issue once last season enter in the bowl, thought it was user error. It occurred once round 1 then again round 3 and now, always on downshifts. I had installed a shift star prior to this round hoping it would rectify the issue, but apparently not......................

So I rip into it; as he stood by talking with some other riders while. Within an hour of work I was able to strip it down and pull the shift forks out to find this...
Left to right 5/6 - 3/1 - 2/4



You can clearly see each one of the ears are worn especially on the 1/2nd's each one's thickness was only ~.05 above factory tolerable specs to be replaced. Also you can tell from the radius shaped wear at the bottom of the 3/1 and slightly on the 2/4 that they are bent as well. The shift drum has no signs of wear and is well within spec. I still need to verify that the gear groves are within spec and the dogs /slots appear okay later today, knock on wood they are. Hopefully it’s just the shift forks themselves, which are already on order ($160).





Well add one more thing to the list, shift drum assembly



Yesterday evening after work I put the bike back on its side in an attempt to inspect the Dogs / slots. While doing to I noticed some lateral movement from the 3rd and 4th. I decide enough was enough, packed up my trailer and went back to CT for the night (no garage here )

1.5hr after I get home...



And the cases are split!


Cardboard is our friend


Pics of the gears / slots. You can see the wear, and the slight rounding on the edged of the dogs

4th



3rd



1st has very light wear and second is just like 3rd and 4th

Got the new gears / dogs in.... Good vs Bad


Right now Im in the hole ~$600. Hopefully when I get home Friday night I can put the bottom end back together and get the valve lashing done in the AM so I'll have time to swap out shims with a dealer. Then Sunday have it back in and running, fingers crossed.

Im still in the hunt for a thinner head gasket, there used to be OEM KIT ones however with a 10yr old bike those parts are now basicly non existant. Cometic only has a .45 which is -.40. I think that might be way to thin i.e. valve clearance issues and to high of a compression. So I might be beat with doing that

Edit: with little time left and coming up short on my searches, I ordered a Comitec .45 gasket

Last edited by MFChop; 09-01-2015 at 11:46 AM.
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post #14 of 19 Old 08-04-2015, 10:01 AM
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Looking good there, Matt. Crazy how much those dogs had worn.

And $600 is an infinitesimal drop in a very large bucket of racing expenses. Be glad that you got off light =)
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post #15 of 19 Old 09-01-2015, 09:47 AM Thread Starter
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Just a quick update, tranny and engine are running great. Only one small hiccup at the moment, my rectifier is running UBER hot at the moment causing some issues. So Im going to be swapping it to the 07-08 MOSFET rectifier.

Also Im taking it to the Dyno Solutions this weekend for a check up / retune since going to the thinner head gasket... Im hoping for a general +1-2 hp from it
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