Another Track build 2014 636 motor in 09 ZX6R - ZX6R Forum
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post #1 of 15 Old 07-10-2016, 01:03 PM Thread Starter
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Location: Danville, VA
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I Ride: Aprilia Dorsoduro, Track: 2013 Ninja 636, 2012 ZX6R
Another Track build 2014 636 motor in 09 ZX6R

Below are a few photos of the two 2009 ZX6R Race Bikes I have essentially built from the ground up.

The most recent build is the Green bike with 2013 race bodywork from my old 2013 Team Green race bike which I turned back into street bike and sold when I retired from the Marine Corps last year.

-I bought the 2009 bike from another member here and quickly found out after buying the triples were bent, calipers needed rebuilt and it started make a racket in the top end after 1 session at a track day....turned out the motor was bad.

I tore the bike down to a bare frame this spring, getting new triples and rebuilding the calipers. With the 09 motor out, I talked with KWS Motorsports and was contemplating a superbike build, but I got lucky and scored a 2014 636 motor for a good price. KWS suggested shaving the head with appropriate headgasket and adjusting the cams.

-For tuning, I used the 09 harness, airbox, injectors, and the Kawasaki Race Kit ECU with a Dynojet quickshifter. We mapped the bike with one tune for both MR12 and 93 pump unleaded. Mike Godin spent at KWS spent about 3 hours on the tuning to get a solid and reliable A/F ratio and tune.....numbers in 90% humidity and 100 degree temps were 134 whp on 93 and 140 whp on MR12.

-The 14 motor externally is identical to the 09-12, with the water temp sensor changing from a 3 plug to two plug and different diameter. We simply retapped the 14 head to accept the larger 09 sensor. While at it we removed the thermostat.

-To run the 13-current bodywork, you will need to change the ram air duct and fairing stay...the 09-12 is one piece while the 13+ is two pieces. You will also need to mount the side fairing brackets to the frame, which involves drilling a hole on the inside of the frame for the bracket mounting....the motor must be removed or dropped down to locate properly. You can probably jury rig some other way, but I wanted to use 13+ OEM brackets.

-I also prefer the 09-12 rear tail section....the subframe is the same from 09-current zx65 or 08-10 ZX10R.....all you need to do is either cut the 13+ battery tray or get an 09-12 battery tray. I did the latter....

-Other mods include:
-Elka triple adjustable rear shock resprung and revalved by Thermosman.
-Ohlins 25mm cartriges Revalved and resprung from forks by Thermosman
-Dynojet Qshifter sensor
-Vortex rearsets
-Dual Carbon race brake pads
- Leo Vince Full Exhaust
-Woodcraft clip-ons
-Vortex rearsets
-Motion Pro throttle
-SS front brake lines
-Graves block off plates
-K/N filter
-2014 ZX6R 636 motor with shaved head, gasket kit.
-Michelin EVO slicks 120/190

















The white/black/camo bike is a myriad of parts and is my primary bike to control ride on and will be used for Endurance racing this year.

-2012 Frame
-2009 Motor with 17k miles
-2004 ZX6R shock linkage with 04 ZX6R Ohlins 46 PRXLS Shock revalved by Thermosman.
-2011 Forks with .95 springs revalved by Thermosman
-2007 Honda CBR 600RR Front calipers with Brembo spacers to fit 310 mm front rotors
-2009 Ducati 1098 Brembo front master cylinder
-SS brake lines from a 2008 GSXR
-VESRAH RJL front brake pads
-Galfer rear rotor
-CRJ Clutch and Brake levers (folding)
-K/N Filter
-M4 Full exhaust
-Vortex rearsets
-Bazaaz quickshifter
-Shorai Battery
-Woodcraft Clip-Ons
-R6 Throttle tube
-2013 Rear swingarm
-Flashed ECU from MRP Motorsports
-Michelin EVO DOT tires 120/190
-Fast by Frank Captive rear caliper
-Fast by Frank quick change brackets for front end tire changes





The white and camo bike is this same bike below that I wadded up a few weekends ago at WERA Cycle Jam, rebuilt overnight, raced the next day with bent forks and bent subframe and still won the Expert Senior Middleweight Superbike Race.

Photo courtesy of Highside photography Link here....last three pages of the 600cc Expert practice capture the stills of the crash
http://www.highsidephoto.com/p413452064
smokey11, TC636, 5hift and 6 others like this.

2012 ZX6R/2009 ZX6R (CCS/WERA Expert #163)
N2 Trackdays, KWS Motorsports, Lucas Oil, Bell Helmets, Woodcraft-CFM
http://www.n2td.org/
http://www.kwsmotorsports.com/
http://www.lucasoil.com/
http://www.bellhelmets.com/
http://www.woodcraft-cfm.com/cgi-bin...i?display=home

Last edited by Evil Cupcake; 07-10-2016 at 01:18 PM.
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post #2 of 15 Old 07-10-2016, 02:16 PM
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Nice. 140HP? Holy shit balls that is the most I think I have read that engine producing.
How much head work was done? Were the camshaft's profiles changed or they are just stock? Great build, great job!!!
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post #3 of 15 Old 07-10-2016, 03:41 PM
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I Ride: 11ZX6R race, 08GSXR750 race, 09KLX110 pit, Zuma street
You sir are an "Evil" racer....

Can't wait to grid up with you....



.
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2010 Wera N.E. / Mid-A. Hwt. Senior Superbike Expert Champion

www.sichertengraving.com - www.Karns-performance.com -
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post #4 of 15 Old 07-10-2016, 04:22 PM
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Nice bike and great power. The still photos are awesome. The cisor comimg off and your head locations are neat to see. Glad you walked away.

2011 Ebony ZX10R-----fast
2013 Kawi Green ZX6R---nimble
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post #5 of 15 Old 07-10-2016, 08:55 PM
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Fantastic! Great looking bikes and 140hp is beastly!
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post #6 of 15 Old 07-11-2016, 07:45 AM
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Quote:
Originally Posted by Backmarker View Post
You sir are an "Evil" racer....

Can't wait to grid up with you....



.
Now that I'd like to see!

Are you guys going to be at the WERA Cycle Jam at VIR in Aug (5-7th)? N2 has a TD on VIR North that Friday and TPM has TDs on VIR South the Saturday and Sunday for us mortals. I was hoping to go.
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Black care rarely sits behind a rider whose pace is fast enough.
Theodore Roosevelt
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post #7 of 15 Old 07-11-2016, 08:23 AM
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140hp is going to chew some people up out of the corners and the in the straights lol. Sick build.
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post #8 of 15 Old 07-11-2016, 09:50 AM
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Quote:
Originally Posted by Off Camber View Post
Now that I'd like to see!

Are you guys going to be at the WERA Cycle Jam at VIR in Aug (5-7th)? N2 has a TD on VIR North that Friday and TPM has TDs on VIR South the Saturday and Sunday for us mortals. I was hoping to go.
Evil and I rode JenningsGP together. Truly was a fun time. He showed me a few lines that helped out a lot. Mr. Evil can rail....

I haven't been racing WERA as their schedule isn't in line with mine.

I am planning the following with CCS;

NJMP July 16/17,
Summit Point Augs. 20/21,
VIR Sept 17/18.

And of course... MotoAmerica at NJMP Sept 9/11.

Maybe we'll hook up again at one of those....


.

2010 Wera N.E. / Mid-A. Hwt. Senior Superbike Expert Champion

www.sichertengraving.com - www.Karns-performance.com -
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post #9 of 15 Old 07-11-2016, 10:21 AM
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Highside Photography....oh the irony! lol

Glad you're ok though, and very impressive that you fixed it all up and won the next race! That's a hell of a build though! 140 hp is pretty damn close to WSS spec!

2007 ZZR600 (sold)
2006 CBR600 (sold)
2010 1198 (parted out across North America)
2013 CBR500R (race bike)
2009 ZX6R (race bike)
2015 R3 (project bike and future race bike)

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post #10 of 15 Old 07-11-2016, 10:29 AM
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Even if I can have one machine like that someday.... Beautiful
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post #11 of 15 Old 07-11-2016, 06:05 PM Thread Starter
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I Ride: Aprilia Dorsoduro, Track: 2013 Ninja 636, 2012 ZX6R
Quote:
Originally Posted by AlexZX6R View Post
Nice. 140HP? Holy shit balls that is the most I think I have read that engine producing.
How much head work was done? Were the camshaft's profiles changed or they are just stock? Great build, great job!!!
Stock heads with just a gasket kit to bump compression...no additional work and stock cams...only properly degreed.
AlexZX6R likes this.

2012 ZX6R/2009 ZX6R (CCS/WERA Expert #163)
N2 Trackdays, KWS Motorsports, Lucas Oil, Bell Helmets, Woodcraft-CFM
http://www.n2td.org/
http://www.kwsmotorsports.com/
http://www.lucasoil.com/
http://www.bellhelmets.com/
http://www.woodcraft-cfm.com/cgi-bin...i?display=home
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post #12 of 15 Old 07-11-2016, 06:06 PM Thread Starter
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Join Date: Nov 2011
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I Ride: Aprilia Dorsoduro, Track: 2013 Ninja 636, 2012 ZX6R
Quote:
Originally Posted by Off Camber View Post
Now that I'd like to see!

Are you guys going to be at the WERA Cycle Jam at VIR in Aug (5-7th)? N2 has a TD on VIR North that Friday and TPM has TDs on VIR South the Saturday and Sunday for us mortals. I was hoping to go.
I'll be coaching on Friday with N2 on the 600.....racing Saturday and Sunday on the 636.
Off Camber likes this.

2012 ZX6R/2009 ZX6R (CCS/WERA Expert #163)
N2 Trackdays, KWS Motorsports, Lucas Oil, Bell Helmets, Woodcraft-CFM
http://www.n2td.org/
http://www.kwsmotorsports.com/
http://www.lucasoil.com/
http://www.bellhelmets.com/
http://www.woodcraft-cfm.com/cgi-bin...i?display=home
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post #13 of 15 Old 07-11-2016, 06:09 PM Thread Starter
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Join Date: Nov 2011
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I Ride: Aprilia Dorsoduro, Track: 2013 Ninja 636, 2012 ZX6R
Quote:
Originally Posted by Backmarker View Post
Evil and I rode JenningsGP together. Truly was a fun time. He showed me a few lines that helped out a lot. Mr. Evil can rail....

I haven't been racing WERA as their schedule isn't in line with mine.

I am planning the following with CCS;

NJMP July 16/17,
Summit Point Augs. 20/21,
VIR Sept 17/18.

And of course... MotoAmerica at NJMP Sept 9/11.

Maybe we'll hook up again at one of those....


.
Thanks old man!!! I only hope I can be at your pace when I am your age. I am racing that "clapper" 600 at the Pittsburgh Steel City Endurance race this weekend. Had I thought about it, I'd have asked you to join the team.

Kick some a## in NJ with CCS this weekend.
Backmarker likes this.

2012 ZX6R/2009 ZX6R (CCS/WERA Expert #163)
N2 Trackdays, KWS Motorsports, Lucas Oil, Bell Helmets, Woodcraft-CFM
http://www.n2td.org/
http://www.kwsmotorsports.com/
http://www.lucasoil.com/
http://www.bellhelmets.com/
http://www.woodcraft-cfm.com/cgi-bin...i?display=home
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post #14 of 15 Old 07-15-2016, 08:10 AM
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Quote:
Originally Posted by Evil Cupcake View Post
I'll be coaching on Friday with N2 on the 600.....racing Saturday and Sunday on the 636.

Looks like they canceled the whole shebang....I guess it must be delays in the repaving.

Black care rarely sits behind a rider whose pace is fast enough.
Theodore Roosevelt
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post #15 of 15 Old 12-31-2016, 09:10 AM
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Got anymore pics of these bad girls Cupcake?
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