2003-2004 Kawasaki ZX6R 636 Engine disassembly and Transmission Diagnosis
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- Опубліковано 30 січ 2019
- This is a complete tear down of a 2003 2004 Kawasaki ZX6R engine that had certain gears slipping while under acceleration. In this video I completely disassemble the engine to the transmission in order to inspect the shift forks, shift drum, and gears.
Motion Pro Clutch Holder Tool - www.motionpro.com/product/08-...
Thanks for watching! Please comment or leave any questions. I'll get back to them as soon as possible! Oh... and hit that subscribe button! - Авто та транспорт
And all the stunt riders said THANK YOU JESUS
😂😂😂 and all the ones who have to go crack a engine open to see if it’s even good
should change his channel to MotoJesus
buying a 636 roller minus the motor today because of Brian and medic
bro i saw ur comment and got excited bc this means its brian approved.
Great video dude! I enjoyed it
Fantastic bro,
I absolutely love what you're doing here man, i've just discovered your channel. ZX6R is a long overdue dream of mine to have. Is the second part of the video featuring issue resolution and engine assembly ever coming out ?
Unfortunately no second video. That bike has already been ripping around for almost two years now and did at least 2 or 3 track days in California last year. I just saw he had it out riding over the weekend too. Still going strong!
I'm a ZX6 guy myself and have had a couple. Happy to answer any questions if you have them. My email is top right of the channel
@@MotoMedic Ah, figures. Good to know it's in good health though~! I appreciate you taking a moment to write back. Thank you kindly for offer also, and best of luck in all your future endavors :) Greetings from frozen-solid Poland
Great video! Very helpful
Glad it helped you out!
@@MotoMedic Hi bro mi 3 gear doestn work... Can i fix it with no get out the engine? Sorry for my english hahaha... I mean fix it taken out gearbox down,by the carter... Thank you so much!!
@@gonzalito1988 not with this engine. It must come out.
@@MotoMedic Ohh sorry i have a 600cc the zx6RR, its the same? Lots of thanks for your time :)
@@gonzalito1988 yup... Same answer lol
hey buddy i got a question coolant came out of my vacuum valves on top of my valve cover on my 2000 zx6r... ever since then ive had smoke coming out the exhaust. do you know why a reddish coolant iquid would come out that valve?
🙌🏽🙌🏽🙌🏽🙌🏽🙌🏽 very helpful. Did you ever get a chance to shoot the assembly video
Wish I did but was pressed for time and didn't end up shooting all of the rebuild.
شكرأ لك على الفيديو الجميل ❤❤😊
شكرا ل كلماتك اللطيفة.
Did you ever get to rebuilding the 636 engine and if so was there a video. I'm a tech myself (automotive professionaly/motorcycle hobbyist) and was/am very interested in the entire process as I currently own both and 03/04 and 05/06 636 that I'd like to educate myself on as much as possible. The first video(disassembly/diag.) was very informative and I'd like to continue watching/learning thru your videos. Anyways lol cheers 🤙🤙
rebuilt years ago and it went straight into the bike it came out of, then spent the next two years as a track bike. I'm not sure if the guy still has it or if he sold to get his new bike.
please tell me you have the rebuild video 🙏
Did you change piston rings, and how good-bad, was cylinder wall? Good video!!!
Didn't even change anything in the top end. Just the bottom end. Everything went back in the way it came out. Bike running beautifully last weekend at a track day and I did this over a year ago.
Is there anything to do to clean the internals/ maintain them?
Just got a 2000 zx6r 33k miles. 2nd gear problem so I'm gonna take care of everything while I'm in there. Obviously gaskets but what else should be done?
Inspect pistons and rings for excessive wear. If it was running fine before then I'm sure it's all good inside but never hurts to inspect things. Best thing you can do while it's apart and out of the bike is get all the valves in spec before stuffing the motor back in. That would be my most important maintenance tip on ANY sport bike. VALVES VALVES VALVES!!!
Nice Video, the fun back in engine disassembly 😅...
I have similar issues with my Zx6r 06 it has a dynojet quickshifter/pc3 on.. gears are definitely not that smooth anymore, secondly it kicks out 2nd gear most times, so when shifting i have to go 2nd then 3rd gear quickly, can u maybe share some light on what could be the problem, have not yet open the motor.
Shift forks start to wear. Gears start to wear. Tight tolerances, don't allow for much wear. It's likely your 20 year old engine. Needs some love
@@MotoMedic thanks for the prompt response much appreciated, I believe it to be the case(Tlc needed), any suggestions on what else to look into whiles the engine is in pieces???
Uhmm two years ago I did the piston rings as well as valve stem seals also replaced piston No:1 as it had a crack.. valve clearance and the intake valves we're grinded too..
Another thing to mention is that the bike spils out black smoke when being revved in stationary mode... Any help will really be appreciated 👏..
I could share some vids if needs be
@@sirginja8579 just give everything you take out a good look and if there are specs to stay in, measure things and make sure they're still in spec. Replace anything not in spec.
Thanks for yet another great vid. Can't find the video where you put the engine back together tho
I never got a chance to record the assembly of this engine before 8 closed up my shop and moved. One day maybe I'll do another 636 and then I'll get the build video done 👍👍👍
Wow! That was a quick reply! thanks bro, keep up the good work!
@@boriscartman I usually reply within 30 min. Notifications come to my phone and I know some people are actually in the middle of a job when they reach out... I try getting back quickly!
@@boriscartman I really appreciate the support to the channel! Thank you!
hey man! i have this bike and problem, so was it the shift forks then? i read how you didn't record the assembly, kinda a bummer but maybe i can find that info. I plan on inspecting my engine this month or next and replacing worn parts.
Yes... the shift forks were garbage. Overly worn and out of spec. Easy to see from the time I pulled them out. Basically... if you have the service manual and work through each step befo0re going to the next one, you're good. Just take your time and never force fit anything. :P
Have you made the second video , I just got a motor I'm going to completely rebuild
This engine is already driving around town... I wasn't able to get much footage of the build unfortunately. Had some camera issues and lost half the video... Happy to answer any questions though! Good place to ask questions also is zx6r.com (I'm on there as PowerGroove)
are all clutch hub holders teeth the same size? years ago I bought one for my 1990 zx10 to hold the clutch hub and I had to grind down the teeth to make it narrow enough to fit in the hub grooves... Are they all the same size or are there different ones because it looks like you placed yours right on there and got busy right away with no modifying of the tool.
I think it can vary a little. Most are pretty close but I've had to do the same thing.
Awseome I must not be so dumb whwn I realize a proffesional did what I did
I have a 2003 Kawasaki zzr600 that I bought and then discovered had the second gear problem rode it once and then the transmission went out. I want to get it fixed but its summer and can't find a shop that will do this. wish it was easier to rebuild it because then i would do it.
Oh man that sucks. I'm sorry to hear that!
When will you post the next video about going threw the engine and putting back together plz and testing stick coils/ignition coils rebuild water pump is need be
Maybe I'll do a video on testing stick coils in the future. But this engine went back together last year and the bike recently got finished and painted and is happily flogged around Bakersfield California almost daily.
Hey! Hopefully you can replay soon. 😅
Doing a rebuild on my 2005 zx6r engine. I’m a total newbie, so sorry if it’s a dumb question. bike has 33k miles and it can’t go above 3rd gear at all. 1st & 2nd feel fine. Shift lever feels stuck after, wondering if I have to take the engine out of the bike to get to the shift forks? Is there a easier way? Or do I need to take it all apart as you did here? Thanks!! Doing this in the next couple days! Hope for the reply soon :)
When was the last time the valves were adjusted?
Thanks! For the quick reply! ... I’m not sure, I’m not the original owner on the bike. Is that what you suggest On doing?
Everyone is telling me if may be the shift forks, would that be you’re opinion as well? Haha thanks so much!
@@trulytony1766 if you're not getting anywhere past 3rd and you're in motion, and the clutch is adjusted properly, then yeah... You might have some transmission issues.
Is it true you can install the cams 180 degrees away since cylinder 1 and 4 are both on TDC, but on different strokes of the cycle? And the motor still run? The cam are still in the correct locations but 180 degrees out
No lol. They can only go in one way. 😊
Wow dam* fast reply… I didn’t think so either. Reason I ask is I just did a gasket seal on the oil pan. Took off the header and noticed on the same cylinders… 1&4, one exhaust valve has some soot and the other exhaust valve same cylinder is clean as a whistle. Valve clearances are within 0.001” of each other… yes I know, I converted to inches…
what about the proper loosening sequence it seems like everyone ive seen does their own thing. the manual for my 2000 zx6r says thightening sequence starts on the inside out but doesnt mention losening, either way you would want to go back and forth between each row of bolts on the camshaft cover...right?
also those head bolts... why do they look so weird and different from a normal hex bolt? also what are thery called and what size socket and type do i need to be able to remove them. i dont want to have to go to every store to every place resource possible buy the wrong stuff and waste money. thanks man love the video.
Loosen the bolts so that the the cam cap(s) come up nice and even. That's all you're making sure of. Slow and steady and don't allow the aluminum to stress. It can crack and then you're not having a very good day. Head bolts might just be 12 point bolts rather than 6 point bolts. So not technically 'hex' head as 'hex' denotes it has six sides. Use a 12-point socket.
thanks homie....beard life!!! I GOT A BEARD TOO HAHA@@MotoMedic
i hope this is my last question. I see how you did the piston gudgeon pin removal what did you use to do that? Do I have to purchase a piston pin puller or is there a makeshift at home remedy? I want my pistons out asap so I can continue my teardown. Don't want to have to wait for tool to arrive in mail or have to spend any money on a piston pin puller. lmk if you can thanks man. also do you have to take both clips out of both sides of the piston?
Head down to harbor freight and pick up a set of picks. Literally just prying the little clips out. But keep a finger over the so they don't fly somewhere in the garage you won't be able to find them lol
What about both clips and the piston puller?
Thanks for your reply appreciate it
I have the picks from harbor freight right in front of me lol
@@josephferris6936 slow and steady buddy. They'll fly away if you ain't careful hahaha
is it possible to access the transmission from the bottom do without the need to fully dissasemble the engine like u did (2003-2004 models)?
I believe it is. I personally wouldn't do it simply based on it being a bigger pain in the ass than removing the engine to have room to work on it.
@@MotoMedic thank you for your fast reply and reading. i still think that if i flip the engine upside down i would have way less work than entire dissasembling entire engine and i wouldnt have to time the engine which is probably the most fifficult part on those engines.
@@timpobega7951 It's really not that difficult to get the timing correct. Just takes a bit of time to make sure you're doing everything right. I personally prefer a full tear down because during the process you can inspect everything else and replace it as you need to. That said... do whatcha want to do. :D I like the later models with cassette style transmissions that simply slide out from the clutch side.
Bad ass video bro
Do you know what might cause that kind of damage to the shifting fork? And what was the resulting symptoms of the issue that led to the decision to rebuild??
Thanks in advance
#636
This particular engine was out of a race bike that had a quick shifter installed. I don't think it was set up properly and because of the abuse of being a race bike without a proper setting for the QS it made it wear out quicker.
For reference, I used to clutchless up shift my 2009 ZX6R all the time. Sold the bike with 50k miles because if done right, it won't damage internal parts. Badly adjusted quick shifter will damage things in a hurry if trying to get into gears at high rpms all the time.
Could you explain why you didn't remove only lower part of the engine to inspect the transmission?
I didn't... The entire engine case is split in order to gain access to the transmission. When disassembling the manual actually has you flipping the engine once or twice to access bolts. It just ends up that way when you pull it apart.
How do you find tdc when a bolt is jammed between the crank? (Could see it from the bottom after taking oil pan off)
Gotta try getting that bolt out so it can turn.
@@MotoMedic that was the cause of the lock up. A bolt from the stator wire cover made its way to the top of the crank.. I don’t think there is any other way to get it out then to split the case
@@codyforster2151 unfortunately I think that's the only option unless there's some miraculous way you can get it dislodged
Can you just flip the motor and fix the transmission? I mean without having to rip apart everything?
No... You can't even access the transmission until the cases are split. In newer models the transmission is a cassette style. My 2009 ZX6 was easily swapped in about 2 hours with the right tools.
Do you know where I can buy a cam cap cover I need one due to a broke valve cover bolt in it
Do you mean a valve cover? A cam cap is machined with the head and can't simply be replaced. You'd need the entire head or it will be a problem.
Hey mate,
Changing my transmission because the gears jumped out (on track)
The forks are damaged and the dogs to, bought a new transmission but I can’t shift the gears while my engine is open (just by hand)
Is that normal ?
It usually has to be spinning to slip into each gear. If you can get the shift lever on and turn the crankshaft to get everything going then it might do it.
Not sure if i need a head gasket ?im just getting a slight burnt coolant smell as. I ride ...no over heating tho
could be a leak dripping onto the block as you're riding.
Hi bud is there a easy way to remove the snap ring on the end of the input gear shaft zx636 or is there a tool I can buy cheers bob
A pair of snap ring pliers will get ya done Robert. Kind of like these....
www.lowes.com/pd/CHANNELLOCK-8-in-Snap-Ring-Pliers/50424410?cm_mmc=shp-_-c-_-prd-_-tol-_-google-_-lia-_--_-pliersandwrenches-_-50424410-_-0&store_code=18&placeholder=null&gclid=Cj0KCQjwoPL2BRDxARIsAEMm9y8z-TzudfonUPhUezfLAH-JTprqcq_qxN876XO9i2eN_XG5Bl5P0E8aAvJjEALw_wcB&gclsrc=aw.ds
Moto Medic hi thanks for that but the snap ring has no holes to prise it apart ?? It’s just a ring with a cut out same as the one on that 636 gear box your about to dismantle
@@robertengland9352 give me a bit to take a closer look. I haven't been inside this engine in over a year 😁
@@robertengland9352 Ahh yes... those little suckers. I think I used a small dental pick to get them out. Don't think I used any special tools. Replace them before reassembling though. They'll stretch a little when taking them off.
Moto Medic hi nice one will buy a set of them 👍 only just come across your channel as I was looking for help on my 636 engine of cause came across your Chanel nice one will keep watching your vids 😁 bob from the uk
Do u know how to temove the bottom rear engine bolt out of a 2019 636 when i losen it tightens cannot fully remove it for some reason its the ine that sits right in front of the shocks in the back lower long bolt
The bottom one is just a long bolt with a nut. Righty tighty / lefty loosy. Make sure you're holding the bolt with something (looks like a hex head bolt) and loosen from the nut side. It might have locktite on it. An impact gun will get it off... of just keep turning, but you have to make the bolt not spin in the there so it has to be held onto.
@MotoMedic I figured it out thanks I had to use a rubber mallet to tap it out the rest of the way it ended up being just that lol thanks again
@@Thugaliciouss awesome... Glad to hear!
Dear sir
I really need some dang help on my 04 636 is there ANY way to get ahold of you for some advice?
Email address is top right of the channel
@@MotoMedic thank you sir got an email sent your way pretty late last night sorry bout that haha
Can this also be applied to the 2005-2006 zx6r?
You would want to get the service manual, but it will be very similar
Was there ever a follow up video for this one made?
Unfortunately not. I got busy and wasn't able to record the rebuild completely. I think I got about half of it recorded before having so much other work going on that doing the rebuild video took a back seat to making the bills. :(
Bike still runs great though and has been doing track days this past summer. Owner was a friend of mine.
I hear that! I can't possibly relate to that anymore. Thanks anyway! Good info in this video.
Nice vid bro I enjoy it but bro can you help me I have problem with my 04 Zx6r
What's the issue you're having?
Moto Medic how I connect you coz it not easy issue bro do you have facebook
@@kakorasheed5589 got your email but it was about 1 in the morning lol. Facebook link is top right of the channel page. You can message me there as well. Send that video through that and I'll have a look
Cam guide can be replaced without head removed ?
Maybe. but I can't remember off hand. All would depend on clearance. As long as it'll get passed everything I'd imagine it could.
I got a 2003 zx6r with second gear going out everyone says i need to replace the hole trans and not just second any thoughts
WIth that year of bike the transmission can't come out without splitting the cases. So honestly... you'll want to change out as much as possible that has excessive wear or damage. And you'll only know what that stuff is when you get inside. The goal is to never have to go back in there.
It wasn't until a few years later that Kawasaki started using a cassette style transmission. I can swap the entire transmission in my '09 with engine in the bike in under an hour with the right tools. Not the case on the '03-'04 unfortunately.
Ever gonna make a video of you putting it back togeather?
@@christianhicks500 The next time I have one I'll do that. Unfortunately sometimes getting the actual work done so I can pay the bills is more important, so I wasn't able to take the extra time to record every part of the rebuild. I tried... but had some camera issues and corrupted files. So I had to scrap it. :(
As far as I know it's back in the bike and shifts great lol.
I will be getting more videos up soon. Some big changes in my daily life coming up soon so there's things on the back burner. But rest assured, there's content coming.
Ive got an 04 zx6r and having issues with false neutral between 3 and 4 and 4 and 5 mainly when im throttling it. Also sometimes can be a bastard to go back into 1 or second from 3 at a static. I've read loads of different opinions online and some a suggesting the star gear and some saying the spring that holds it inplace could be gone or damaged. Any ideas? Thanks
How can I get you to do my motor? I think my transmission is bad 😩 what’s your info?
I'm located in north Idaho. Unless you're somewhat close to that, I don't think it's worth it to ship a bike to me lol. But I'm very happy you want me to get my hands on it 🤣
Please post news videos about the cb900c 1982 :(
I'm workin' on it man! I run a business first so almost everything I post is a customer's bike. Slowly churning through the paying gigs to afford materials and parts for the CB project. Rest assured I've got more video I'm editing for this project so stay tuned for more in the very near future!
Anything in particular that you'd like to see in the next video??? Please sound off! I like to know!
Thanks for the comment!
@@MotoMedic Okay ;). I buy next march a CB900C with 61 000 miles on it as my first motorcycle, I guess it will need a rebuild soon and I need videos with good quality images and well explains like yours to prepare me before I get it. They are pretty rare for this exact bike! So yeah, it'll be very useful to me when I'll have the bike. You deserve a lot more subs for what you make!
Thank you again ! ;)
@@skywarser1610 Well my friend, you're in luck because the next installment of the series will be going more into the engine. Yes! These are much more rare than the 900F models. Thanks for the compliment on the channel! I appreciate it! Feel free to tell your friends to subscribe too :D
I will have to really refer to this video when I go to take my baby apart. I’m not looking forward to this AT ALL!
However, I must thank you in advance for all the help 😂
Hahaha... Well I'm glad it'll help you in some way. Hit me up if you have any questions!
Thank you so much! I will
Question, why didnt you paint mark the cam chain? Arent you gonna need to retime the motor??
Making the chain is a nice way of keeping your timing if you're just pulling the cams. If you're pulling the entire thing apart it doesn't matter much. There are other methods to get it in time. Marks on the cams, TDC, and counting links on the chain 👍
@@MotoMedic thanks for letting me know man also can I split the cases without taking off the head
@@chasemcclary8861 don't think so... Never thought to try. It's actually less work with the engine out.
@@MotoMedic OK thanks haha I need to rebuild my transmission so I thought I might as well do it myself even if it takes months to do it
@@chasemcclary8861 it's really not that hard but very meticulous and time consuming. My best recommendations are to make sure you have the factory service manual, and a nice, clean area to do the work. You'll need a couple of special tools but not a lot.
Can you spilt it with the head still attached?
Nope. Head is bolted to the cylinders, which are bolted to the crankcase. Cylinders have to come off. Can't remove those without removing the head
what did I do wrong?
DIY maintenance
Replaced parts and general maintenance:
GASKET,HEAD COVER
GASKET,GENERATOR COVER
GASKET,CLUTCH COVER
GASKET,PULSING COVER
GASKET, OIL PAN
oil change
spark plug change
coolant flush
throttle cable
air filter
Results: starts normal,but before when I started the engine, it started with high RPMS and RPMSt went down too idle RPmS as it warned up and now it starts with low normal idle RPMS,(which one is normal...??)
-after second gear feels like the throttle disengage and the bike does not go faster till I shit to third then throttle responds, the same thing happens from 4th to 5th gear(I did not any of this issues before I did the maintenance)
First of all... Thanks for subscribing! You're my 1000th subscriber 👍
The only thing that jumps out at me after reading what work you've done is the head cover gasket. Because you have to pull the air box off to get in there thata the only place that would be a source of your problems.
I would pull the tank off, take the air box back off and inspect that you've got no cracks in the boots that connect it to the throttle bodies. Your symptoms almost sound like there's air getting in somewhere. Make sure everything is back together snug and doesn't have any leaks. Rechecking all your plugs and stuff while you're in there.
It's probably something simple if the bike ran fine before you did the work.
@@MotoMedic Thanks for the advice, I will do so and report back
The shift forks etc would be nice it they were made out of titanium.
bike would be too expensive
Then we would all have MotoGP technology. I'd rather have a seemless gearbox. :D
I need ur help! With my 03 zx6r plz
How can I help?
Hello Broo, I have One problem one my 636A 2002. He in every gear on above 4k/5k jump. Like 1 teath in gears is broken but only on that mutch rpm i change a Clutch basket but it's same, do you have myby Email or time to help my because i dont know what is problem,sorry because of language
What gears are missing teeth? Your drive sprockets? I'm not understanding what you're trying to explain.
@@MotoMedic i want to say feel is like one transmission(gear) teath is broken but teath are good on every gear,and bike good over 5k rpm and under 4k rpm only betwean 4-5k rpm jumping
@@MotoMedic Medic? You are Balkan Guy or?
@@sjevki6006 Most likely because it's a sport bike and they don't like being down that low in the RPMS. A loose drive chain can make it seem jumpy. A bad throttle cable adjustment can make it feel jumpy. If it needs a tune up it could feel jumpy at that RPM. Many factors....
If you had missing teeth in the transmission that bike wouldn't move.
@@sjevki6006 Nope... 100% gringo American living in Mexico half the time!
What does a head gasket cost to get replaced on a 2005 zx6r ...what is a fair price
you'd be looking at a pretty good sized bill. They should be able to do it with the engine in the bike but you're probably in about 6 hours labor time at least.
Subscribed*
Thanks man!
@@MotoMedic nah man thank you.
I'm having a really tough time with my 2013 636's electrical and recharging system... it's not turning over, check engine light on and cluster is flashing all weird and idk where to start... anyways, all knowledgeable resources are appreciated and you seem pretty knowledgeable.
If there's any advice you might have I'm all ears but I'm the mean time keep up these bad ass videos.
People like you deserve a big thank you for your time and effort. Yall out there turning inkling squids into track monsters one video at a time. 🤘
@@MackSmooth I had two 2009 ZX6R's and they're not much different than yours aside from the ECU, 37cc's, and wiring harness. You basically have two main things to check. Stator and regulator/rectifier. Do yourself a favor and download the service manual for the bike.... There's a section on ZX6R.com with manuals 👍 There are some test procedures you can easily try if you've got a multimeter and some basic knowledge.
Thanks for the compliment and share the channel with friends! May actually have some track stuff on this channel in the future lol.
@@MotoMedic I cant even start with how much that helps bro. I was about to just buy a new Rick's but I wasn't sure yet... at least not $200 sure. Now I can pull out my multi meter and figure out specific what went wrong.
Thanks again for the help and for the quick response. I'll share this allover fb and zx636 pages.
Rock on 🤙
@@MackSmooth I've got over 10k posts on that website lol.... Powergroove is my screen name on there. I think this video is posted there but I don't know haha. Knowledgeable guys on there... Especially Riverszzr. He's rough around the edges but knows more than most.
Yo what's up with that cluth master tool
You talking about the vise-grip looking thing I'm holding the clutch with? Motion Pro clutch tool....
www.motionpro.com/product/08-0008
Are you in Michigan? I need to find a mechanic to fix my 3rd gear
I'm in Idaho... Cost ya more to ship it here than for me to rebuild it lol
@@MotoMedic lol..fair enough.. would you know any trust worthy peeps in Michigan?
@@viperwavstudios let me do some digging 👌
How come you never made a reassemble vid
Because making videos takes a lot of time. I ran a business. That came first.
@@MotoMedic r u mt certified and if u are, is it worth it
Wheres the rebuild vid???
Read the comments... I think I've answered this 15 times
NEVER TO RUN AGAIN.........LOL
Thanks for this one... and the other idiotic comment. This bike has been running track days for the last three years on this rebuild. And wearing gloves while working on an engine is pretty common with professional mechanics and technicians who have to work with actual clients and look like they're professional business owners. I also like when my lady wants me to stick my fingers in places.... it's helpful to have clean hands. (Not that you'd know anything about what it is like to have a woman actually want you to touch her) ;) Have a great day!
Why can't you just pull the bottom of the case off while its in the bike? I have to do mine trans and im scared bc she got over 60k and someone else has been inside for sure
My approach to these things is this: Kawasaki spent hundreds of thousands, if not millions of dollars figuring out the best way to make, and service these bikes. If the factory manual says to do it a certain way that's how it must be done.
Also.... Good luck getting the bottom of the case apart and even completely unbolted from top half without the engine being out.
It's always best to be able to cleanly work on an engine. Sometimes you have to use gravity to your advantage and flipping an entire motorcycle upside down to get a better look at what you're doing seems like a lot more work than the 90 minutes it takes to get the motor out 😉
Where’s the assemble and conclusion of the problem?
Hey Man... I wish I would have gotten the chance to put together a video of the build, but unfortunately was way too pressed for time. The issue was definitely the shift forks which also gave the gears they ride in excessive wear. Luckily we had the owners spare transmission from his previous engine. I spec'd everything to make sure it was good and ended up building the motor in an evening. It was a friend of mine's bike. He came by and picked up the engine and stuffed it in with a friend. Ran great... no shifting issues or slipping out of gear.
Watsaf
okie dokie!
Or do you mean WhatsApp? I do have WhatsApp but I'm not giving that number out. :D
Thanks for your video, but you did all that work just for shift forks? You did not need to remove the top head of the engine, pistons and all that extra works. You didn't even need to pull the engine to swap forks. You just needed to drop the exhaust, oil pan and the clutch, the rest can stay on the bike. Read the service manual folks, it will save you tons of time. 😅
First of all... your comment makes absolutely no sense at all. In order to diagnose what was wrong with the transmission, you do have to split the case. It's in the manual. Or didn't you read it? This year of ZX6R did not yet have a cassette style transmission that was easily serviceable from the side of the engine. You can't remove the shift forks the way you're explaining it. I'm a master mechanic, bud. I'm pretty sure I got this down.
@@MotoMedic You had me doubt myself there for a moment with your confident reply... but after having done the work myself just now, I am correct. Have a look at 9-26 of the service manual. I just swapped the shift forks on my 03 636 B1 without splitting the case, so I am correct about that. You can also evaluate dogs and gear teeth without splitting the case or dropping the engine. Removing the drum from the clutch side of the bike should let you visualize the output shaft and even measure it. Even without doing that, it is somewhat visible with a boroscope which is what I always do to save on time and repairs. The input shaft is completely visible by dropping the oil pan and gently laying down the bike on the side.
I'm not questioning your competence as a mechanic. Maybe best practice says to open apart the whole engine and inspect it and moreover your video is a godsend if you have trouble north of the transmission.. Also few people are crazy enough to open their own engines let alone make a youtube video about it... but I'm trying to say there are other ways and your video gives the impression this is the only wayy. Sure if you want to pull the shafts out the tranny you will need to split the case, but even the service manual says that the cylinder head is to be removed only if the crankshaft is to be removed... if you suspect the gear engagement is the only issue, you can even feel the forks with your hand to check for wear.
@@arnobashtar6707 You should start a youtube channel then. Since you're so good at this and you have such a winning personality you might make some money with it.
You have no idea what else was done to this bike so you really can't tell me how to do my job. Have a great day and thank you for watching my videos.
@@MotoMedic No that's fair, sorry for my tone in the first comment, my intention wasn't to tell you how to do your job, just wanted to put the info out there for the folks.