TL Tech Pro Shop Other 2006 Kawasaki Ninja ZX-6R Restoration And Upgrade

2006 Kawasaki Ninja ZX-6R Restoration And Upgrade

2006 Kawasaki Ninja ZX-6R Restoration And Upgrade post thumbnail image

This bike was purchased over the Internet from a dealer roughly 2,000 miles away from our shop and delivered here via a transport service. The bike arrived in good shape, however whenever we buy a used bike, we rebuild or replace anything that is not up to specifications. This bike was going to be used as a track bike and needed to be 100% safe and reliable.

Items We Serviced Or Replaced

  • Coolant Flush/Replaced With 50/50 Water Wetter/Distilled Water
  • Replaced Thermostat And Gasket (OEM)
  • Brake Fluid Flush/Replacement (Front & Rear)
  • Changed Oil (Fully Synthentic)
  • Replaced Oil Filter (OEM)
  • Replaced Air Filter (OEM)
  • Replaced Brake Pads (OEM) (Front And Rear)
  • Replaced Tires
  • Balanced Wheels Front And Rear
  • Replaced Spark Plugs
  • Cleaned And Rebuilt Brake Calipers (Front and Rear)
  • Rebuilt Water Pump w/New Mechanical Seal and Gaskets
  • Replaced Chain
  • Cleaned Fuel Injectors And Replaced O-Rings

List of modifications and upgrades we made to the bike to make it safer for the street and faster at the track.

  • Braided Stainless Steel Brake Lines (Front And Rear)
  • Front And Rear Sprockets (OEM Specs)
  • Front Master Cylinder
  • Tank Grips
  • Servo Buddy
  • Rear Cowl
  • LED Turn Signals And Brake Light
  • Quickshifter
  • Engine Cover Protectors
  • Front Fork Sliders
  • Frame Sliders
  • Lithium Ion Battery
  • Battery Tender Connector
  • Radiator Hoses And Hose Clamps
  • Tail Tidy
  • Safety Wired Oil Drain Plug, Oil Filter, Coolant Reservoir Cap

Tech Tip
If you are working on a bike that has been sitting for several years, it is extremely important to change the brake fluid and replace the seals in the calipers. When we rebuilt the calipers of the ZX-6R we found a lot of build up inside the calipers caused by water that was absorbed by the brake fluid. We thoroughly cleaned the calipers, replaced all of the seals, and installed new stainless steel brake lines.

Parting Thoughts

The water pump mechanical seal will eventually wear out and fail. Replacing the seal can be made a little easier by heating up the old seal with a heat gun, then using a removal tool to carefully extract the seal. The water pump case can be easily damaged, so take your time and do not force it. The biggest improvement we made to the 2006 ZX-6R were the brakes. The stock front master cylinder was not very good even after we rebuilt it. We were extremely impressed with the Brembo 19RCS Corsa Corta, it improved our braking power on the track and made street riding much safer by reducing the braking distance of the bike.

Vendors For Parts

  1. Stainless Steel Brake Lines – Galfer FK003D459R-CL-SL, FK003D459-2-CL-SL
  2. Sprockets – VORTEX (#3288) , VORTEX (#452A)
  3. Chain – EK Chain 520 MVXZ-2 Quadra-X Ring Chain
  4. Front Master Cylinder – Brembo 19RCS Corsa Corta
  5. Radiator Hoses – Samco Sport Silicone KAW-72-BU (Hoses), CKKAW-72 (Clamps)
  6. Quickshifter – IRC (Upshift) IRC-CUT-KAWASAKI-A
  7. Tank Grips – TechSpec 62-0041-SS
  8. Integrated Taillight – TST Industries 05ZX6INTC
  9. Front Turn Signals – Amazon Front Turn Signal NoCut For Kawasaki Ninja ZX 6R 10R 14 Euro Light Blinker Clear
  10. Turn Signal Relay – Custom LED ELFR-1
  11. Tail Tidy – R&G LP0011BK
  12. Lithium Ion Battery – Fire Power Featherweight Lithium Battery HJTX9-FP-IL
  13. Frame Sliders – R&G CP0139BL
  14. Front Fork Sliders – R&G FP0229BK
  15. Tires – Dunlop Sportmax Q3 Plus
  16. Rear Cowl – eBay Rear Passenger Pillion Seat Cowl Fairing For Kawasaki Ninja ZX6R 2005 2006 ZX636
  17. Servo Buddy – 421112
  18. Engine Cover Protector – R&G KEC0061BK
  19. Mirrors – Amazon MZS Motorcycle Mirrors Rear View Compatible with ZX6R 636 ZX-6R ZX6RR 2005-2008

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