Kawasaki ZX6R 636 Rebuild PT2. - Engine Rebuild

[@superbikesquadracer]

Respect for what you do! Love and passion for motorcycle! Jesus bless!

[@zrcarbon9937]

Thanks man 🏍️🛠️🤘

[@victorserna9039]

Geat job is amazing how you can make it work and how you remember each bolt in right place. I tried but lots of left over bolts.

[@josephferris6936]

im going tot use your video as a visual aid to my process thanks man

[@zrcarbon9937]

I’m glad you’re found my video useful for your project.

[@phoenixisbister7871]

been waiting for video like this thank you

[@zrcarbon9937]

Thanks so much. I’m glad you’re finding it useful for you 🛠️🤘

[@calebstiegler1017]

You put the butterfly valves in opposite how you took them out/ the last thing you bolt on. In the beginning they where face down. At the end the are facing up and sideways. I’ve never worked on these but it’s not how you took it out.

[@calebstiegler1017]

42 seconds into the video and 20mins 2sec to see what I am talking about

[@zrcarbon9937]

Yes you’re right. I did place those breather valves upside down. I have no idea what I was thinking at that time. Thanks for the shout out! 👍🏍️🛠️🤘

[@Row02]

Nice video, it’s gives ppl an idea of how it’s done. Gotta learn somehow

[@The2fix]

Great job men, i’ve done it too, but you’ve done it better! 👌🏼

[@zrcarbon9937]

Thanks man! 🏍️🛠️🤘

[@vaclavhejda5658]

Nice video! Very professional 👍

[@701Gangstatainment]

17:39 you have like 26 pins looks like you timed the intake cam wrong

[@yusabayrakoglu3824]

Clean job, i liked it

[@Saucethe1]

No valve shims?

[@FromTheGroundUP627]

Yer I noticed that too

[@ftlw1433]

Why no valve lapping? Do you have any videos on how to ream/cut/lap valves and seats for this engine?

[@zrcarbon9937]

Hey not for this engine.🛠️🤘

[@victorserna9039]

Can you help me.? How to remove and replace new piston.? How do you remove it? Is the same motocicle. Zx6r 2005

[@victorserna9039]

Thank you very much.

[@zrcarbon9937]

Hey You have to use heat for the pistons to remove them. Also I suggest to buy the Haynes manual. The engine is slightly different than the 2005 model. If you have any questions send me an email to [e-mail]

[@josephferris6936]

awesome how did you know the loosening sequence for the camshaft cap? I watched your video just praying that you would show this specific step to loosening the cam shaft cover because its a big deal. thankfully you were thorough enough to do it and show it thank you soo much. my kawa manual for my 2000 zx6r which I believe the motor to be almost identical only shows the tightening sequence but i knew it had to be wrong for loosening. now I can confidently go ahead and loosen the camshaft caps. lol you called them crankshaft bolts lol thats funny you meant to say camshaft cover bolts ANyway I am extremely grateful for your directions and video thank you. How did you know to loosen them that way is my real question?

[@zrcarbon9937]

Hi I just used the Haynes manual. That book has so much information. The book also showing the tightening sequence and the loosening sequence. If you only know the tightening sequence for your bike I should do it the reverse way. The last bolt you’re tightening should be the first bolt you’re loosening and working your way backwards. I hope it makes sense. I watched the video about a hundred times before uploading it and I didn’t notice the crankshaft until you just told me 🤣 Some how my brain just doesn’t notice that. 🤷‍♂️ I’m extremely happy you’re using my video for your build. I wish you the best of luck for your project. 🏍️🛠️🤘

[@josephferris6936]

@@zrcarbon9937 no problem i finally got it off.. now i have to figure out how to get the tensioner cam guides out. no mention in the manual about it

[@kieferguthrie1828]

Other than OEM is there anywhere you would suggest looking for engine parts. I have a 2003 Zx6r 636 as well and it needs a rebuild. I’m not against OEM, it’s just super expensive.

[@zrcarbon9937]

You can find gaskets on EBay or just have a look on google. Type in zx6r B1H gasket. 🏍️🛠️🤘

[@anthonyvallejos3723]

how difficult would it be to remove the crankshaft and replace from where you had the pistons exposed? recently had my crankshaft lose a couple teeth 😢

[@zrcarbon9937]

Hi I’m sorry to hear that. From the point where I got you just have to split the crankcase. I suggest to buy the Haynes Manual for the zx6r and read the subject many times over and over till you understand that. Also buy everything what ever the book suggests to rebuild the bike, and you won’t have any problems with the bike. Than it should be a straightforward job.🏍️🛠️🤘

[@701Gangstatainment]

why did you install the reed valves in backwards they got taken out?

[@dpoobq]

You have done great work Thank you for sharing your experience can you kindly share the link for the gasgates rebuild kit

[@zrcarbon9937]

Hey Thanks for the compliment I’ll be uploading the link by next week 🏍️🛠️🤘

[@zaitharanda8347]

A mi también me seria de mucha ayuda el enlace! Excelente trabajo! 👌

[@DJBLESSD]

What the cause of the problems? What I could see was a strip Clean And re gasket Cheers

[@zrcarbon9937]

Hi The valve stem seals were leaking. Flooded the engine slowly with oil. The carbon built up slowly in the combustion chamber. It was a disaster. Needed a big clean 🏍️🛠️🤘

[@DJBLESSD]

@@zrcarbon9937 interesting man cheers 👌

[@chubbybunny7612]

justo esto estaba buscando, gran video me encanto, no se si después tengas oportunidad de desarmar un Kawasaki ZZR600 o si ya tengas un video sobre eso

[@phoenixisbister7871]

great job. the only difference i would have made was to take the cylinder head to a machining shop for a professional re-surface

[@zrcarbon9937]

Thanks for the compliment Yeah I would loved to do a couplet engine rebuild. To replace everything and to take most of the stuff to the machine shop to resurface and get them done by professionals. Unfortunately I was running on the budget. I only paid 350 dollars just for the gaskets and the oil seals. 🤯 Soooo bloody expensive Hopefully in the future I’ll be able to get a complete rebuild done Thanks so much for watching 🛠️🤘

[@FromTheGroundUP627]

I didn't think he did anything wrong other than he could have carried on sanding a bit more to get all the equal, i did see a few rough spots around the edge, using a ruler afterwards and using a feeler gauge to check it's level was the next step but he missed that and it's crucial before the rebuild.

[@mickl8212]

The only time you resurface a cylinder head or block face is if the surfaces are damaged or warped. Not just get them skimmed for the sake of it.

[@kraft-moto1413]

Does the cam cap not seat all the way down to the head or as you tighten the bolts in sequence in snugs up ?

[@kennq507]

Thinking of doing mine what was the actual time span spent on this motor? & could it have been done quicker had done in one sitting?

[@zrcarbon9937]

Hey Yes, I think it can be done. But you have to have all the new parts ready to go for it. 🏍️🛠️🤘

[@josephferris6936]

one more question what kind of head bolts are those? their not hex and they have weird shaped heads. what kind of socket do I need to undo those bolts?

[@zrcarbon9937]

That’s called dodecagon head bolt. You have to buy a special socket. Those bolts need a size 10 socket. Dodecagon socket. 🛠️🤘

[@josephferris6936]

your awseome bro thank you could have spent a lifetime stressing trying to figure that out... I GOT A BEARD TOO YOOOO BEARD LIFE @@zrcarbon9937

[@thegodsofthegods877]

What are the bath for valves and what size socket for cylinderhead bolts? 9mm?

[@zrcarbon9937]

Just some heavy duty degreaser and the sockets are 10mm 🏍️🛠️🤘

[@fr0uv3n]

please dont turn the crankshaft without installing the cam chain tensioner

[@H427-m4y]

Why?

[@fr0uv3n]

@@H427-m4y because of the timings, they can get wrong if not enough strength is on the timing chain

[@ahadqayamali9542]

Awesome video. Did you end up replacing the exhaust flange studs with oem? And what gasket set did you use? I’ve been trying to find the Athena complete set but it appears to be unavailable everywhere I look. Thanks :)

[@zrcarbon9937]

Hi Yes I did replace the exhaust studs with new. You can find aftermarket studs on eBay or even on Amazon for a reasonable price. The gasket set I used was sourced from Germany. Still it was very pricey but not as expensive as the OEM gasket sets Here is a link for the gasket set 🛠️🤘 www.ebay.co.uk/itm/134622335435?chn=ps&_ul=GB&_trkparms=ispr%3D1&amdata=enc%3A1FSnJsbMARIepUZH2aOWvwA79&norover=1&mkevt=1&mkrid=710-170020-547209-2&mkcid=2&itemid=134622335435&targetid=293946777986&device=m&mktype=pla&googleloc=20135&poi=1000936&campaignid=20784045347&mkgroupid=157398042404&rlsatarget=pla-293946777986&abcId=&merchantid=109864583&gclid=CjwKCAiAqY6tBhAtEiwAHeRopbQYSjs5VnZUHdiPWQBO6bATiUyeEsT56qIOX19J4LavGl23U_zRfxoCyi4QAvD_BwE

[@genarogranados3093]

So I have to take the motor out in order to change the head gasket????

[@zrcarbon9937]

Hey Yes you should do that. I suggest to buy the Haynes manual.

[@genarogranados3093]

@@zrcarbon9937 thanks

[@phillewis7910]

Awesome tutorial thanks.

[@zrcarbon9937]

Thanks!🏍️🛠️🤘

[@diken8089]

Sir No position in oil and compression rings ? Allredy Randomly installed

[@zrcarbon9937]

Nope Not randomly

[@Row02]

Did you not do new cam chain because you tensioner wasn’t reset when you put it back in

[@zrcarbon9937]

No I didn’t do new cam chain. Oem parts are super expensive and I didn’t see the point to change that since had no problem with it. Thanks for watching 🛠️🤘

[@HalfdeadRider]

The cam chain will last many miles they rarely need changing on a well maintained engine.

[@davidramnarine9090]

Great job! What gasket kit did you use and do you have a link for it?

[@sebastiankoder23]

Athena gasketkit

[@markconlon814]

why didn't you re seat the valves?

[@stephen8385]

exactly, tearing the engine apart, cleaning all the carbon, changing the valve seal and measure the valve spring but not re seat the valve... duhhhh

[@michaellynch9576]

Did you need to change piston rings

[@rex6311]

so you didn't grind the valve seat and reuse the old piston rings?

[@zrcarbon9937]

Hey Yes. Everything looked really good. The bike doesn’t have a lot of mileage. 20k only The issue was the carbon built up in the chamber. I used the same pistons and rings. Probably I’ll get a full build when I reach another 40k miles. Thanks for watching 🏍️🛠️

[@jamesfoster3488]

We race 600 micro sprints. We run 05/06 kawis. I’d like to learn to do the rebuilds myself as it’s one of our more costly aspects of racing. Was this hard to learn? Where are you located?

[@zrcarbon9937]

Hey That’s cool you would like to service your race bike. You should invest into a Haynes Manual. Makes the whole work so much easier. It has all the details what you need to service or rebuild your bike. 🏍️🛠️🤘

[@AndrewStricklen]

That screeching when you tighten the head bolts means you didn't lube them. It also means a leeking head gasket in your future

[@zrcarbon9937]

Good banter 🤣

[@AndrewStricklen]

Trying to save you some $

[@markhouston3404]

Dont lube head bolts. The torque settings are for dry bolts. That creak is normal for any stretch bolt. Crack on

[@michaelruegg209]

Head bolts are torqued dry. Lubricant causes a false torque reading, often quite a bit higher than specified.

[@TrickersCSM]

Is this a common thing on the 636 from 2006?

[@motomafia7485]

I got oil leaking out of my exhajst header and air box what does that mean ? Would you know

[@zrcarbon9937]

Hey I believe you have the same issue as I had. The valve stem seals are leaking through oil. I had soo much oil going into the air box the combustion chambers and the exhaust. Was burning oil but not enough to see the oil level drop dramatically. I hope this was helpful If you have any other questions just ask 🏍️🛠️🤘

[@MrJimmie87]

Did you reuse the head bolts? or did you buy new bolts?

[@zrcarbon9937]

I reused the same head bolts

[@jaydangle2]

love this video newly subscribd and own an 04 636 . where did you find the music for this video???

[@zrcarbon9937]

Thanks so much for the support. The music is from epidemic sound. 🛠️🤘

[@prestongilbert7393]

Where did you find the rebuild kit?

[@zrcarbon9937]

I found it online. A German company was selling it. In Europ is difficult to buy any of these but the US market is loaded with aftermarket parts for zx6r. I have a few links in the description below the video.

[@sammydiaz-i1q]

I’ve been looking for parts rebuilding 05 636 any recommendations?

[@zrcarbon9937]

Hey What type of parts are you looking for and where about are you based? 🏍🛠🤟

[@paulcalabrese2727]

Tip when cleaning is oven cleaner where ever there is a lot of carbon build up…stuff breaks it down like nobody’s bussiness…

[@zrcarbon9937]

Thanks for the tip! I’ll do that next time 🛠️🤘

[@laurengilby5070]

Hey there, this video has helped a lot, just wondering what year is this?

[@EduMDR]

qual site para comprar peças do motor?

[@markhouston3404]

Red loctite on cam gasket! You wanna hope you dont have to take it to bits again. A bit of rtv would have been much better, and cheaper. The only other thing i would have done is lap the valves seeingvas you went through all bother of stripping down engine, and you went at them with a dremel. Other than that good to watch

[@DenverLatawan-w9o]

I wish Kawasaki make a naked Version of this bike

[@Gu3ssWhoki113dU1]

Do you/ anyone in the comments know what to do if you over tighten the valve cover bolts and brake a peace of cam cover

[@zrcarbon9937]

I’m sorry to hear that ☹️ If I understand right the bolt didn’t break. You should replace the broken cam cover. But if the bolt broke as well you have to take off the cylinder head and drop it down to the local machine shop. They will get that bolt out for you. I hope this is was helpful. 🏍️🛠️🤘

[@Gu3ssWhoki113dU1]

@@zrcarbon9937 yes it sure was, and yes the blot is fine just broke alittle of the cam cover

[@H427-m4y]

Actually, this is fuckin cooool 😪🔥

[@iimecho]

dang the valves part seems not fun to do

[@philhill7973]

Didn’t lap the valves in!

[@zrcarbon9937]

Hey Yes I didn’t. I didn’t have the budget to buy some shims so I left it as it is for now. It runs great. 🤘

[@manuelbegarin3398]

Et le sondage de soupape 😮

[@bobanppvc]

Gsxr 600 engine design is so much better...You can reuse mls gasket and buy new parts for money saved

[@zrcarbon9937]

That sounds good! Never heard about that. I may have to get going a gsxr project🏍️🛠️🤘

[@robertoudokrapf453]

OLÁ - 17/11/24 Negativei por diversas discordâncias Técnicas. O Assunto estará em livro no ano de 2025 sem identificar a marca, modelo nem autor dos erros. Será citada penas a data de hoje.

[@sabercruiser.7053]

🔥🔥🤌🤌🤙🤙

[@zrcarbon9937]

🏍️🛠️🤘

[@colboysigmax]

Good clear and useful video but it honestly didn't need the music. I had to mute practically the whole thing.

[@aleksandrby1006]

20,03 мин на оборот поставил 🤣

[@JimCoutts-e8t]

Get rid of those gloves.

[@zrcarbon9937]

👌

[@satinderpalsingh649]

Valve laping missing 😮, 🤏

[@zrcarbon9937]

Yeah I didn’t lap the valves. That’s for another time