hey guys just a question, i just acquired an 04 zx6r, ive heard the 05/06 head has bigger ports and the cams on the 05/06 have a more aggresive grind... is this true and what will i need to do to make the swap complete?? the more info i get the better thank you...

 

the 05-06 had different head designed than the 03-04 did but the 05-06 cams will work in the 03-04 zx6r, its basically the kit cams that kawi sells for the 03-04 636's, good for extra mid and top end power

 

pm speed138 he has done quite a few 05-06 parts on his 03-04, the only thing that i heard was different are the 05-06 cams are the race version 03-04

 

yup what he said.

 

P.M. Crasher986 . He just did this with is bike. He can tell you exactly what you'll need do do the swap.

 

I just got mine back on the road recently. It's an 03 with 06 head and cams. Valves are bigger, cams have different profiles (I guess... That's what I've been told at least) and most importantly the intake ports are polished up real purdy! I think I read in a mgazine once that there is a room full of Japanese women porting ZX6 and ZX10 heads all day long at the factory!
Everything between the top ends will swap out with the exception of one very important thing. You will need to get a Cam Position Sensor to fit the new head. This sensor will not plug into the existing plug on your wire harness. If you know this ahead of time, you will not feel the urge to set your bike on fire and watch it burn to the ground. The new sensor has a pigtail plug as opposed to the earlier model that is all one piece molded together. I wound up pulling the wires out of the 06 sensor plug and just sticking the leads into the plug on the harness. Then a couple zip ties hold the whole thing together and a wad of electrical tape to keep water out. When you look at the plug head on, the plastic part in the middle will pull out. Then the wires can be removed once you use a pick or small screwdriver to release them from the plastic outer piece. You may be able to cut a couple relief cuts into the plug and make it fit into the wire harness. I was eager to get mine together and tired of trying to make work, that's why I went the redneck engineering method!
Easy way to go is just swap the cams. You should be able to do that with the engine in the frame.
If you go the whole way, be sure to get a new head gasket. New valve cover gasket is cheap insurance since you're in there. Same with exhaust gaskets. These are all interchangeable, buy whichever year you are happiest buying. I used my 03 valve cover on the 06 head, in fact. Intake boots are the same. I forget if the thermostat cover is the same. But it will swap out between heads. There is a bracket that holds one of the wire harness plugs that will need to be swapped to the t-stat cover on the new head.
You will want totear downthe new head and clean it. I found a intake boot screw inside once I pulled the intake valves! That would have been expensive! Buy new valve guide seals (16), for sure. I got new valve keepers (32) just be absolutely sure. I also lapped the valves into the seats, just because.
I went to the shop on Thursday to run it on the dyno. But with the WERA Cycle Jam here at Road Atlanta this weekend, they were jammed up with race bikes and couldn't fit me in...
Runs great on the street, pulls strong. Seat of pants dyno checks out!
I put a new cam chain in there, also. Once again, just because. Have to split the cases in order to do that. Probably not worth the effort to be honest.
This was a little long and maybe a bit rambling, so if you have any specific question please let me know.Don't think I skipped anything important. Hope I didn't scare you off of doing it! This was my first time doing anything in the head.
If I were still living in West Palm, I'd give ya a hand for sure!

 

Thanxs crasher.. good info.. yea the thing is i have an 06 zx636 runs hard i love it, but i wanna build a sick 03-04 and i heard the bottom end is practically the same just that the 05-06 heads flow better and the cams for sure... the reason im doing this build is b/c the 03-04 are lighter so im guessing 03-04 bottom end, 05-06 ported head, stock 05 cams, by the way yea im going with the manual cam tensioner, still debating whether get the kawi one or the ape, im also going to run the kawasaki race ecu so i can do timing, air/fuel... im also doing the 05 swingarm and front forks... my goal is to scare some 750's down here show em some kawi power... i hate gixxersss... so as much info i can get will help me out...

Thanxs...

 

Sound like you'll have a potent 04 636. I have a Race Kit ECU up for sale on ebay if you're interested. It's already programmed and ready to go.

 

+1, alot of good info there, almost a DIY writeup

 

I'm pretty sure the entire bottom end is the same part numbers. You can swap the 05-06 trans into the 03-04 in order to put the slipper clutch in. Speedracer has or is planning to make the switch. The only difference is the longer input shaft on the newer trans in order to fit the slipper clutch. In fact, the input shaftmay be the only part different in the entire bottom end.