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+--- Thread: 636 - PROJECT 03/04 gas tank on a 05/06 (/showthread.php?tid=38574)
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636 - PROJECT 03/04 gas tank on a 05/06 - Petarded - 04-13-2012
Started this new thread for organization purposes between the head swap and the gas tank swap.
Came up with this idea from balancetheory's "05-06 head on a 03-04 636" thread... http://stuntride.com/vbstunt/showthr...87#post1284587
Quote:
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Originally Posted by Petarded
 IF... the above is true ... the airbox and throttle bodies from the 03/04 also fits 05/06 head.
THEN ... the 03/04 gas tank could possibly then fit the 05/06 because the main holdup is the bulky 05/06 airbox. |
So far I have determined to do the 03/04 tank on the 05/06 you need...
03/04 throttle bodies, airbox, tank, mod to tank mount, and slight mods to harness.
This is what I've figured out...
In order for this to work you need the 03/04 throttle bodies on to the 05/06 head. (The 05/06 bodies are obviously oval shaped at the top so the 03/04 box will not fit.
The throttle bodies are almost exactly the same (aside from the top shape... i imagine you could swap just about everything back and forth) The 03/04 fuel rail is different and the injectors harness on the 03/04 comes to one molex plug... whereas the 05/06 does not have a molex and just comes from the harness (so you just unplug the 03/04 molex and injector plugs then toss it to the side and plug in the 05/06 ones)
CATCH ... Not certain if it is necessary to swap the fuel rail on the throttle bodies to mount the 05/06 line to the second set of injectors and custom fit them to the 03/04 airbox. First I'll try quickly extending the fuel plug to the 03/04 pump (the one from the 05/06 is far too short to hook up to the 03/04) then see how she runs just with that single rail. I'll see how that runs first and if no dice then the 05/06 throttle body fuel rail and airbox injectors would need to be custom fitted to the 03/04 airbox and throttle body.
Ok so now to the 03/04 tank (I used one of twites old tanks) ... it is shorter and imo it looked silly scooted back to the 05/06 seat mount because the front part was all open (I should have taken a pic of it) Either way the bracket to the 03/04 mount will need to be cut/modified and a custom bracket will need to be made for the tank to mount properly one way or another.
The pics below are with the 03/04 tank lined up with top the 05/06 mounting point.
Tank will drop a bit once the mount is cut and a bracket will need to be made to the stock mount.
The seat was SO close to fitting even with the tank like this... BUT once the mount on the back of the tank is cut it should drop and the seat will fit perfect!
PICTURES...
For now I'm just going to mount my non dented tank after everything is painted so I can ride... but I'll be working on this tank project within the next few weeks.
And just to plug SMD and Aaron Twite's work... Here is my new 05/06 Full fairing SMD/Twite frame that is going out for paint this weekend.
636 - PROJECT 03/04 gas tank on a 05/06 - Paul - 04-13-2012
might have to figure out some sort of "cutting board" mod for this once u get it all sorted. good shit tho man!
636 - PROJECT 03/04 gas tank on a 05/06 - Petarded - 04-13-2012
Quote:
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Originally Posted by Paul
might have to figure out some sort of "cutting board" mod for this once u get it all sorted. good shit tho man!
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636 - PROJECT 03/04 gas tank on a 05/06 - GIL with 1 L - 04-13-2012
04 zx6rr has second set of injectors in airbox
636 - PROJECT 03/04 gas tank on a 05/06 - Petarded - 04-13-2012
I'm unable to find anything to confirm this... the throttle bodies on the 03/04 only have one output fuel line ... i suppose they may have changed the throttle body and the airbox on the rr but i'm unable to find any images showing this... =/ hmm
636 - PROJECT 03/04 gas tank on a 05/06 - MiNi GuineA - 04-13-2012
Quote:
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Originally Posted by Petarded
I'm unable to find anything to confirm this... the throttle bodies on the 03/04 only have one output fuel line ... i suppose they may have changed the throttle body and the airbox on the rr but i'm unable to find any images showing this... =/ hmm
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636 - PROJECT 03/04 gas tank on a 05/06 - GIL with 1 L - 04-13-2012
Quote:
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Originally Posted by Petarded
I'm unable to find anything to confirm this... the throttle bodies on the 03/04 only have one output fuel line ... i suppose they may have changed the throttle body and the airbox on the rr but i'm unable to find any images showing this... =/ hmm
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636 - PROJECT 03/04 gas tank on a 05/06 - Petarded - 04-13-2012
Unfortunately (as much as I wish you were right)... I pulled up the microfiche from two different sites for the 04 zx6rr and both only show one line coming out and no airbox injectors. =/
04 zx6rr (looks the same as the 03/04 zx6r)
From...
http://www.kawasakipartshouse.com/ka.../I11I1194E1130
Like I said earlier though the throttle bodies are so similar I should be able to add the rail from the 05/06 to the 03/04 but the airbox will need some serious cutting and modding probably have to just cut each and mount the 05 top on there or something.
05/06
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http://www.kawasakipartshouse.com/ka.../I12I1246E1515
636 - PROJECT 03/04 gas tank on a 05/06 - Petarded - 04-13-2012
Does make me wonder IF i have to run the T with the extra injectors ... I may have to mount the 05/06 fuel pump to push it as maybe the 03/04 isnt sufficient enough.
anyone ever try to fit a 05/06 pump in an 03/04 tank?
636 - PROJECT 03/04 gas tank on a 05/06 - WheelieJoe - 04-13-2012
I built an 03, and went to fit my 05 pump, and the connection plugs are different. Only a 5 min job to join the 05 plug to an 03 pump.
I didnt have an 03 plug to put on my 05 pump, so I didnt try any further than that.