KZ900 to 636 front end swap

Bama704

Member
I am taking my '76 KZ900 and doing the swap to a 2003-2005 kawasaki 636 (zx6r) front end, I already have my KZ stem pressed into the 636 triple and it fits like a glove. I need to make the decision on using the clip-ons, or running some risers, would possibly need a new top triple to do this though. For the rear I have a gs100e swingarm that I will be doing sometime as well. Right now the fender for the 636 looks like absolute crap IMO and doesn't fit the look I want to get. I want something small that follows the tire and is affixed to the brake brackets using minimal metal, is this something I would have to more than likely make my self, or does anybody know of a place where I can buy this for my setup? It would look similar to the fender on my triumph.
I don't have the capability to form any sheet metal which is why I'm asking if I can buy it.
 

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doc_rot

Oh the usual... I bowl, I drive around...
DTT BOTM WINNER
Cool, bike. Just a heads up but the 636 forks are pretty short in comparison to stock. These ol KZs are wide as hell and they need all the ground clearance they can get. Its possible to lengthen the forks internally.

You can run high or low rise adjustable clip-ons. I run the low rise clip on from Tarrozi https://www.fastfromthepast.com/clip-ons/high-rise?p=1

You can buy a cheap fender blank and work out the mounts yourself. something like this. https://www.ebay.com/itm/Motorcycle-Silver-Aluminum-Front-Wheel-Fender-Mudguard-For-BMW-R-NINET-14-19-R9T/233353601855?hash=item3654f5633f:g:kNUAAOSwafddjc9H
 
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Bama704

Member
Thanks Doc. Appreciate the links that's what I'm looking for.
I was looking for zx9 forks but these fell into my lap, if I need to switch at some point after riding I could always look for the longer zx9 forks, or search for options on lengthening them internally. I was hoping that the 636 front end wouldn't be too much shorter since I already had my top triple dropped down about 2 3/4 inches in the tubes to begin with.

I'm sure you hear this frequently, but the detail you put into your 1000 is bonkers, truly a beautiful bike and thanks for taking the time to document along the way.
 

doc_rot

Oh the usual... I bowl, I drive around...
DTT BOTM WINNER
thanks for the kind words

heres a link to lengthening forks for the future if you find you need to do that. its for a zx-7 but it should apply.
 

doc_rot

Oh the usual... I bowl, I drive around...
DTT BOTM WINNER
thats hot. Tad bit more expesive but hten you could correct the offset to be better at the same time.
 

Bama704

Member
Yup, that is pretty damn good looking right there. Got the second brake rotor and caliper installed yesterday. I may have to look into getting that top triple (in due time), looks like there are plenty of companies out there who make these.
 

Bevelheadmhr

Member
DTT BOTM WINNER
The top yoke in the pic was made by a mate of mine, in his home workshop. Not sure how much it cost, but it wouldn't have been silly money. That said they are never going to be cheap, as you have to start with a thick block of alloy and then a lot of machining labour to get to the final shape.

Here are some pics of it being made..
006.JPG
z650 029.JPG
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