2005 Kawasaki ZX-6R Timing Chain Overview

Just put a new timing chain in our ZX-6R and just wanted to point out a couple things to show people who might consider doing this job for themselves OR people who might already be stuck right in the middle of doing their timing chain.

[@garymaartens8061]

As you showed us here, keeping tension on the cam chain with your hand while tightening the cam caps works great. It doesn't tell you that in the service manual. I've used zipties before and they worked, but there's no need for them and it just makes the job longer than it needs to be. A trick I use when doing valve adjustments is to strike a white line on each cam sprocket and link in the chain. If I have to pull the cams, I use these lines to put the cam chain back on. I still double check my timing marks, this just takes some of the guess work out of placing the chain back on the sprockets with correct timing.

[@DeffectiveMirrors]

One thing you left out is to put your thumb by Cylinder 4 and check if it's on the compression stroke. The manual does a bad job at explaining that the engine is being timed with Cylinder 4 on the compression stroke. Cylinder 1 is at TDC but not on the compression stroke. That 1,4 TDC marking can be misleading if you don't understand that both cylinders can not be on the compression stroke at the same time.

[@DanJDT1]

Thanks for the video. I'm about to try my first timing chain on my 02 zx6.. This helped a bit.

[@casmitherz]

I have so many projects going on at one time I just try to hit the highlights. :-) I had to get this bike back together and back on the road quick too. I just never found any good definitive info online so I made this video to hit some of the main points that aren't very clear in the Kawi repair manual. Just spin the engine over a half dozen revolutions when you are done and make sure every tooth and chain link is on the dot before you button it all back together.

[@jl2w711]

ok i will have to check it out. thanks for the reply and the video. it would have been nice to see all of it but i understand it takes a lot of time to record and everything. Thanks for the tool down the whole tip i will have to try that.

[@casmitherz]

This is an awesome video I just found for you. He uses a ZX-6R for this how-to. Make SURE you download the service manual for reference to double check any advice anyone gives you online! There are way too many people posting bad information and everyone assumes it is correct. I'm sure you will be able to do this yourself. Just take your time and double check EVERYTHING. I will private message you the link. Search " Valve clearance inspection on a inline 4 motorcycle (example: Kawasaki ZX6R) "

[@casmitherz]

1st there is a tab from the engine cases that keeps the chain on the crank sprocket at the very bottom. If you grind or cut this off then you will not have to take the engine out of the frame to do this. I won't tell anyone to do it this for safety reasons. BUT I cut mine off and I don't ever expect to have any problems. It's there to prevent major engine breakage in the event that your timing chain tensioner breaks or your timing chain wears out so bad that it can skip a tooth on the sprocket.

[@casmitherz]

Totally. A clean engine is a happy engine.

[@rafaelara123]

Oh Yea feels great, and feels better than before since I cleaned all engine.

[@isbemorph]

I'm not 100% sure but i think the cam chain tensioner 3:13 needs to be removed before reinstalling the cams you've detailed. And once they're torqued then install the tensioner back, make a full turn to take up the slack, and check the alignment marks. Its the tensioner's job to properly tension the camchain, not cams. And on some models tensioner needs to be out even before reinstalling the cam cover, while Haynes totally misses that.

[@casmitherz]

Right on. Feels good to have it done huh?!

[@casmitherz]

Hey there, well to make sure it's TDC #1 on any engine you can put a thin rod or tool down the spark plug hole of cylinder 1 to see if the piston is actually at the top of it's stroke. At the top of my forum just click on the "Additional Projects Area" and you will find the timing chain replacement ZX6R thread. My username on the forum is Smithers. I don't have step by step instructions on the forum... it takes way longer than the making of this video. Don't be in a hurry doing this!

[@KararAsi848]

😮😮😮

[@frankusquiano5875]

Great video you just save some valves lol thank you señor mr Smithers

[@casmitherz]

+Victor Lopez Glad to help out. When reading the steps in service manual it's kind of hard to follow. It's not as hard as it seems but it's gotta be right on. These are extremely strong engines but the chains and guides will make noise at about 30K and you can bet on it.

[@michor10]

Great info, man. I wish I had the knowledge and gear to do these kind of things. *sigh*

[@casmitherz]

@michor10 Dude this is not easy stuff! You have to have the right tools and know how an engine works really well plus be able to recognize any problems that might be inside the engine by looking at wear and tear on components. This is a tricky little engine! Which is why I wanted to post this vid.

[@edwardburke5486]

Question if the timing chain gos this motor is considered an interference motor which can cause valve damage because of valve and piston contact when it gos correct or will it not make contact with valve and pistons ??? Thinking of purchasing one with a blown timing chain but want to make sure it’s only the timing chain that needs changing and no further damage to motor like valves and so on. …. What does everyone think on this issue ??? Any information I’m real thankful for don’t want to get stuck with a bike that is all messed up if it’s just the timing chain that’s not too bad but further damage I’m trying to stay away from summer is almost here I want to ride not get stuck working on it through the summer with further damage and problems thanks again for any help and information with this issue

[@user-um8hq9vm8f]

This is an excellent video! I have the same bike, set up the exact same and from what I can see. A can lobe in cylinder 4 in your video. Mine are not the same. (Keep in mind, the markings are the same, and the cam shaft sprocket identifiers are the same) WTF?!

[@luross2057]

how did you take the cham chain sprocket off to replace the chain.?

[@fly1ngpapaya]

you did the modification to the bottom to remove chain without splitting cases before on that motor and I was wondering if it's possible on a 98 99 zx6r. I know the exhaust guide rests on part of the lip to the right but can you remove enough material to remove chain without compromising lip for chain guide?

[@fixntoteachya]

Question in the service manual it doesn't specify having the gasket on,I've notice in your video the marks are more accurate with it on. So I'm guessing line the marks up with gasket on? Thanks for the vid

[@KararAsi848]

❤❤❤❤❤

[@benryan4819]

Thanks for great tips. I just wonder, how do I need to turn the timing for positioning #4 piston to get the inlet valve clearance of #2 and #4 cylinder, and exhaust valve clearance of #3 and #4 cylinders. I am kind of nervous here..

[@jacky1tse422]

I have a 2012 kawasaki 250 that vibrates at 8-9000rpm on highway when i am cruising at 70mph, i can feel it came from the engine. The engine does have some tiny metal chain ticking noise when first start. I think the cam chain tensioner need to be adjust. But other then that do u think the bike has some other issues from the engine to cause the high rpm vibration?

[@NeeoDroid]

Thanks for the video man!! Lol why they make it so hard to do in the frame damm I'll try again for the third time. It doesn't want to run right seems like i'm off 1 tooth or something. I didn't hold the chain down too either and noticed and it was "loose" on the cam gear while i was dooing the torque pattern

[@felixh2709]

I did it last week on my zx6r 2005 in frame. The problem is that you can't see the timing marks correctly in the frame. That's why you have to make two strokes on both sprockets before removing the camshafts and always keep the chain under tension towards the top. If it loses tension and jumps a notch below, you have to remove the entire motor and adjust it as described in the video!

[@NeeoDroid]

@@felixh2709 lol what? 😂 You don't have to remove the motor. I did it2 weeks ago, took both cams out and just re timed it. Since the cam timing marks are on the outside, I just used a paint pen and made the line on the other side. Then you count the number of link (dots) on the chain.

[@jl2w711]

im in the middle of doing mine and im not totally sure if i have tdc set right. I have the marks lined up but how do i know its its at the 1 or the 4? Also i tried checking your website. Wasnt able to find your thread. You user name for this youtube account didnt come up and either did what you named this video.

[@ryanmorrow1631]

I like my ex with the upper surface of the head and and count 28 pins and put my IN on it and tighten cradle and the IN doesn’t line up with the upper surface? Confused

[@jonsmith7426]

You bent the cam shafts. You put cams in and torqued. Then timing chain.

[@MoodSwingZX]

I had my case spit in 2003 b1h. Replaced the tensioner and chain. Wish they havent used non endless chain.

[@georgestam1710]

What symptoms did u have before changing? My B1H has very bad vibrations at 5-9k rpms, loud ticking and grinding when decelerating with pop and flames from exhaust... I suspect chain is too lose and fucked up timing....

[@MoodSwingZX]

@@georgestam1710 noise even on low rpm. Sory for late replay.

[@georgestam1710]

@@MoodSwingZX haha it's ok buddy.. actually almost some days after my comment, replaced to a manual cam chain tensioner and everything was fine, until some months ago that one of four bolts, at coils, got loose and touched the rotor at 16000 rpms.... Debris and small metal parts from coils and the bolt, sat on oil pump screen, low oil pressure and fried bearings.. i removed the engine, splitted it, but got boring and now she is sitting in my garage with a cover, to not even see her 😂😂

[@sancak099]

l have kawasaki zx636 2004.do we haf to take off engine from the frame for the change timing chain? pls help

[@rafaelara123]

I'm gonna try this with my 98 zx6r it looks the same. My chain broke while I was at red light.

[@MoodSwingZX]

How did ir work with the cut out peace?

[@angelojannetta6758]

Does anybody know if the engine has to come out

[@jerryx2000]

do I need to take out the engine for this?

[@casmitherz]

Jayden Valentine Ask the dudes over on the forums. I imagine pros probably swap cams without taking it out but if your changing the timing chain... engine is coming out. It's not that hard! Take pictures with your phone and you can reassemble anything!

[@thiboutotsimon2823]

Men it suck doin this engine mounted on the bike

[@NeeoDroid]

have you been able to do it? I'm trying to do it with a little miror and light haha

[@karenlyflo]

It varies the time of each motorcycle or they all have the same time

[@casmitherz]

Karenly Flores You gotta check you service manual. 😊

[@drewb242]

Not so fun with the engine still in the bike. You cant see the marks on the cams at all, they are too close to the frame.

[@rafaelara123]

you think that would work even if the chain broke

[@rafaelara123]

I just got my bike running again

[@casmitherz]

@rafaelara123 Very good. You just have to remove your engine and pay attention to details. Wow that's lucky that yours broke at a red light. I hope your valves look ok. You'll find out when you remove your cylinder head. Check out my website at Fourwheel Forum d0t c0m and you can find my thread in which I show how I did it. Good pictures so check it out if you need help.

[@dakotaneidecker7995]

Bought the bike from a squid so it no came with a manual brother