2023 Kawasaki ZX-6R STG Project Bike

It’s been about four years since our last Project Bike—the Yamaha R7. For our latest build, we wanted to do something a little different from our previous projects, which all started as brand-new, zero-mile motorcycles. For the 2026 STG Project Bike, Brian Van will be resurrecting a salvaged 2023 Kawasaki ZX-6R 636, transforming it from a crashed street bike into a fully track-prepped machine.

In this project, we're taking you through the entire process—from tearing the bike down and checking out the damage, all the way to our boy Max Van ripping hot laps when it's done. The Kawasaki ZX-6R got major updates in 2013 and again in 2024, but here's the cool part: most parts from the 2013-2023 models still fit the 2025! That means these install videos will stay useful for ZX-6R owners for a long time. We're loading this build up with the best from Vortex Racing, M4 Exhaust, Spiegler Brake Lines, Armour Bodies, and more — so make sure you stick around!

The big news is this STG Project Bike is being sponsored by two great companies who also sponsored Max Van's MotoAmerica SuperSport racing in 2024 and 2025 Precision Track Days and 2 Wheel Dynoworks! As we move through this project we will be sending the ECU out to Nate at 2 Wheel to have it flashed and installing some velocity stacks they have developed. Once the project is complete Max will be spinning laps with our friends at Precision Track Days to see how the ZX-6R stacks up against the Next Gen Suzuki GSX-R750.

In this video we serve up a preview of many of the aftermarket goodies and OEM replacements we will be installing on the ZX-6R to get it ready for Max to ride.

This is the first "How To" video for our STG Kawasaki ZX-6R Project Bike. In this video Van shows you how to remove every OEM body panel with the exception of the front fender. Almost every modification or maintenance item you will perform on your ZX-6R will require body panels be removed. The OEM kit on this bike is modular and has several pieces along with multiple fastener types. This video covers every clip and fastener used to retain the OEM body which will be helpful if you are reassembling your bike and do not remember where every fastener goes.

We recommend this video to be used as a reference for all projects that require body panels to be removed. In future videos we will not cover panel service as closely as we have here.

In this video we begin with a replacement set of front forks already installed on the ZX6R and work through Brian's process when repairing a bike that has a bent set of forks from a crash. After the forks were installed Van breaks out his HealTech Laser Chassis Alignment System to show how to check the headstock for the frame and how to make sure both of the used froks that were installed are straight. This is not a tool that is in production any longer but one we use all the time on our race bikes. Everytime we align the rear axle this tool comes out to ensure the rear wheel is perfect.

Next up we will be removing the forks and triple clamps to inspect and service the triple clamp bearings.

In this video Van goes through the process of removing the Triple Clamps to inspect them as well as the steering stem bearings to make sure they can be reused. He found the parts to be in good working order and walks you through cleaning and lubing the bearings so the Triple Clamps can be reinstalled. The most important step is preloading and torquing the steering stem nut. You need to get this right so the steering moves freely but does not have any play in the bearings.

Next up we will be replacing the radiator that was damaged in the crash and refilling the coolant system.

In this video Van goes through the process of replacing the damaged OEM rear swingarm. Both of the spool mounts were damaged in the crash before we bought the bike which make it hard to support the rear of the bike with a stand. Like many other projects this one was not without it's challenges. One of the bearings on the swingarm we purchased from a salvage yard was bad. Fortunately the bearing in the one we took off the bike was in perfect condition and Van was able to remove it and install it in the replacement swingarm.

Next up we will be replacing the radiator that was damaged in the crash and refilling the coolant system and installing the M4 Full Exhaust System.

In this video Van installs the M4 Kawasaki ZX-6R / 636 09-26 Tech1 Carbon Standard Mount Full Exhaust System on our project bike. In our opinion (supported by our friends at 2WheelDynoWorks.com) this is the best full exhaust system for the Kawasaki ZX6R. M4 is our number 1 selling exhaust brand for many reasons and the only exhaust we use on our track bikes here at STG. This video shows you all the steps it requires to install this on your ZX6R.

Next up we will be replacing the radiator and running through the process of purging the air from the cooling system.

In this video Van replaces the radiator that was damaged in the crash. If you are installing a full exhaust on your bike removing the radiator will get you more access to get that done while protecting the radiator this video will serve as a helpful guide. This video also covers all the steps to change the coolant and remove air from the system to prevent overheating.

Engine Ice Hi-Performance Coolant is our best selling coolant here at STG. Most trach day and racing organizations allow this and it has freeze protection so you can leave it in all year if you live in a cooler part of the country. Engine Ice is also excellent for use in street bike.

Woodcraft is one of our very best selling hard part brands here at STG. Everything is built and designed here in the US and it is one of many brands we are proud to offer. TheWoodcraft Kawasaki ZX-6R 19-26 Rearsets Complete Kit Standard Shift are the perfect choice to dial in the foot controls on our ZX6R Project Bike. Our plan with this kit is to use an aftermarket quick shifter so we are able to do that with this kit by flipping the shift knuckle. This kit offers all the adjustability we will need to dial in the ergonomics so Max Van can get the most out of the Kawasaki.

This rearset kit will be one of many Woodcraft parts that we will be installing on our project bike.