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Free/Cheap mods for the 03-06 636's

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113K views 235 replies 64 participants last post by  davidajohnston83  
#1 ·
hey guys here is a list of mods i put together that i have done to my 04 636 that will improve the performance and power for all the 03-06 636's. if anybody has any questions feel free to ask and i will try and answer them the best way possible.

1. KLEEN Air mod - where you reroute the pair valve breather located on top of the valve cover to the crankcase breather, plug all vacum ports on the airbox so it will let you pressurize the airbox, also gets rid of the popping & backfireing you hear thats most common with a aftermarket exhaust system & helps smooth out the throttle through out the entire rpm range

2. Ram Air mod - consist of removeing the resonator located underneath the ram air tube, you want to plug the hole back, this allows for the air to enter through a straight path without disturbing the airflow

3. Airbox mod - consist of removeing the dirvertor thats locate inside the airbox in the middle, you will need to drill out the 2 holes that holds the dirvertor inside, plug both holes back up, this "unrestricts" the air flow path to the throttle bodies given it a more staright flow, good for more top end power

4. Velocity Stacks - remove the 2 "tall" oem stacks in the middle for 2 "short" oem v stacks, this way you will be runnin all 4 short, good for more mid-top end power & thats where our motors like to be

5. Secondary flies removed - this consist of you takin the top airbox lid off when you look down inside the throttle bodies the 1st set of flies you see you want to remove them, make sure you dont let the lil screws fall down off inside the throttle bodies/motor best to use a magnetic screwdriver when removeing it prevents this of happen, this mod is good for more mid-top end power & better throttle responce
 
#2 ·
I'll play devils advocate here;
Did you do baseline dyno runs and then do a mod and verify that it actually did improve performance on your changes, or is this just your thoughts?
Say before and after of your airbox mod?
Before and after of your velocity stack hieght change?
Before and after of removing the resonator in the airbox inlet?

Also-Kawasaki does sell solid dowel pins to replace the hollow ones that fit under the valve cover and allow air to pass from the "KLEEN" into the exhuast port-you can find the part number in their race parts-they will fit almost any kawi.
 
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#4 ·
they all will do something but each on there own will have little but all will make a nice change.. just try some and see if you can tell the difference
 
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#6 · (Edited)
^ placebo effect?

The only true way to verify if anything has actually made an improvement is with a baseline and then an after run under controlled conditions.

I have a dyno and have done thorough testing on hundreds of bikes- I just want to know what the OP did to verify if anything he is suggesting actually made a real repeatable and verifiable improvement.

"i did have the bike dyno tune with all these mods along with a full exhaust done to my 04 636 and it put down 120rwhp." So what was your baseline number?-120 means nothing without a comparitive figure. What are other bikes making on that same dyno?

"
 
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#12 ·
Knerona-has the best answer here.

AAron and ZXRACER, my point was and still is, where is the proof of what these changes will actually do for improvements. I am not saying they don't work-I am playing devils advocate because it is so easy for anyone to say "I fealt a big difference" when all too often there really isn't one, quite often the mods people do make there bikes even less powerful where you use it in everyday riding-but.....( a prime example is loosing midrange performance and then feeling a "hit" at say 10,000 rpm's that wasn't there before and thinking wow look at the performance improvement....when in actuality it was a performance loss)

ZX I actually own a dyno-so other than time costs and actual electrical usage it is free to me, and since you have access, I assume you work somewhere who has one, so dyno time for you should be free/cheap...unless you just mean someplace close to you will run your bike for you? And most dyno facilities have some day where they run bikes for $20 a run or some such "promotional bullshit". I do as does nearly ever place with a dyno near me.

I have done testing of many "mods" on many different bikes and some of these mods actually don't help, they actaully loose performance (much like the example I gave above), while others actaully do make improvements-some more noticeable than others.
The ZX6 jumper mod is certainly one of those that actually gives the most noticeable of gains without sacrificing performance in the midrange-that would be tops on the list for an actual "free" mod that actually works and benefits you.

ZX-what was your dyno numbeer before any of those mods??
 
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#14 ·
Riverzzr is right you need to have a point of reference . i did the secondry flies removal and im sure that if i didnt have the advancer on the bike it woulod suffer too much coming out of slow bends so where that would maybe be a good mod for the 1/4 mile it wouldnt be so great for the cucuit in my opinion as its exactly as riverzzr said what happens is the bike power comes like a switch low end you have no power then when power comes on you feel that its a lot
 
#23 ·
I went through this list a while ago and got sorta cornfused. #3 on the list says to remove the diverter in the air box, well neither my friend's, brother's, nor my own 06 636 (yes we all have one) had any type of diverter in the air box. in fact with a good flash light it is possible to see the air filter through the ram air inlet on all three from the factory. So we all just taped the frame holes and reassembled.

Was this diverter only on the older models? Or am I missing some thing?
 
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#25 ·
yes the dirvertor was on the 1st gen 636's but if you dont see a dirvertor in the middle inside your airbox then yours dont have it. just tape up the holes inside the frame and do the rest of the mods and WOLLA new found of power for a lil of nothing :devious

landspeeder said:
The mods that ZX Racer are talking about are all proven. They work. The more air you can get into the engine, the more fuel you can put in. Tune it up and the more HP you make.
Click to expand...
Thank you landspeeder :) i personally no these mods work very well on the 03-06 zx6r's. ive spent countless hrs on the dyno and tuning my 04 to get the most power out of it possible.
 
#24 ·
The mods that ZX Racer are talking about are all proven. They work. The more air you can get into the engine, the more fuel you can put in. Tune it up and the more HP you make.
 
S
#32 ·
Not to buzz kill, but in earlier posts, you stated you did no "before" dyno for a base. Then in the last few posts you stated you pent countless hours tuning on the dyno. Just trying to see what you base line was when you first started. I intend to try some of these, but curious where your base started before the countless hours. Also if I were to replace the shorter stacks with tall, would that bring some kick to lower rpm band? Again just looking to clarify.
 
#41 ·
when i 1st bought my 636 i didnt dyno it to see wat she was puttin out bc i went straight to modin her to my likings but your right i have spent countless hrs on the dyno to no wat works and wat doesnt work. just try the mods and you will see for yourself that they work and im sure you will be happy with results :devious
 
#33 ·
Pretty much all of these mods will give you a very very small boost in power, which would be very hard to detect, given that there will be different temps and humidity on the different days you would dyno. Those factors alone would have a greater effect on power. I have no doubt, though, that most of these mods would positively affect power. It only takes a simple understanding of how motors work to see that.
 
#43 ·
roc916 said:
MJS HEADER FROM MJS PREFORMANCE:cuckoo:
STEERING DAMPER FROM MOTOMUMMY:)
SWING ARM SLIDERS
STEEL BRAKE LINES FRONT AND REAR COLOR-SMOKE
HID'S 35W DUAL 6K- DDM TUNING:thumbs-up:
SMOKED OUT WINDSCREEN
RIM WRAP- BLUE
Click to expand...
may i ask why you post this :O and wat this got to do with cheap/free mods bc none of these mods you posted is def free or cheap :coocoo

NickySixx36 said:
This is a thread about cheap/free mods?

How is any of what you posted helping this thread?
Click to expand...
+1 :O
 
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