Hey i thought you chaps over the water might like to see this.
As every one knows the 636 front ends suck. They snap off , crap brake and do forks seals continually.
Well Tee-Rex and me noticed how simular the R1 front end is (1998 -2001) after measuring up all ya have to do is bore the bottom triple clamp 2mm bigger in diameter and the whole R1 front end just bolts in.
I now have great brakes,much better feel while doing stoppies and a strong as hell front end.
The forks are only 5 mm shorter than the stock 636 which is no big deal and i used the stock 636 master cylinder.
The machining of the triple clamp for a machine shop is only 45 mins work. I know as i run the family engineering buisness.
What do ya think guys ?
Oh yeah the later R1 front ends have 15 mm shorter forks so prob are not so good.

 

I would never put inferior, outdated Yamaha crap parts on my bike. Glad it worked for you but me putting Yamaha trash on my bike? I would have to sell it and never live down the embarassment.
I would just put a newer set of zx6r forks on or sleeve the ones that came on it.

 

You obviously never rebuilt 636 forks. They are built to a price plus i have later 05 forks on my other 636 and that pops fork seals too !! The old R1 forks are a quality fork. plus they are not made by yamaha on R1 s
Not saying ya wrong melloyello just my

 

I have rebuilt plenty of forks, none of my own. I have had 2 bikes and never had to rebuild my forks. Old one had 12,000 miles and this one has 20,000 miles and haven't had any problems w/ them since 2003. But, I keep an extra set around just in case I need them.
But, I am just saying I wouldn't put anything off a yamaha on my kawasaki. I don't care if it was made by Yamaha or Ohlins or whoever. If it came off a Yamaha it ain't going on my bike. It's just my opinion. I am glad it worked out in his case but it's just not for me.

 

why do you have such a hardcore grudge against yamaha..? ohlins is ohlins weather its on a yamaha or kawi

 

I get the feeling ya wont be poping down ya yamaha dealer any time soon then eh

 

Just don't like yamaha, sorry. They are at the leading edge when it comes to stylish design but when it comes to technology they always take a turn in the wrong direction. Most parts used on their bikes have the same technology as other makes of years past. Their engineering is completely backward from anyone else. Who in the world needs velocity stacks that move? That serves no purpose. And they have ridiculous ways of matching engine internals. Just look through a manual and try to figure out what bearings you need. Everything yamaha does is in reverse if you ask me. Work on enough and you see that they may be pretty but.......
I worked at a dealer that sells yamaha, suzuki, kawasaki, and honda so yeah I will be at the local dealer but not looking in the direction of a yamaha.
Anyways, let's not get too far off subject. This may be an inexpensive fix for some people so just post up comments about the fork swap.

 

05/06 forks are showa as well as the 07/08. i never popped a fork seal on my 06 nor on my 05 and i just put on 07 forks cuz i didnt like the gold color and wanted thew nissin calipers and these are fine too. ive never seen any problems with any of the 05+ forks