Ninja ZX-6R Engine Disassembly - Part 1 of 3

[@nignisaqua]

Thank you for the effort you've put in making this videos. As many other said, this is are very helpful

[@lotlizardz8218]

i need to swap a head from another 03/04 motor to my bike and this video is all i needed, thanks!

[@zc240x7]

Hello drew - lookinass

[@tylerburcham6824]

I know this is an old video but thanks so much I was concerned about timing and the cams and this helped a lot

[@pkdann64]

Thanks for watching and glad it helped!

[@Mynameisntyomomma]

Love this video. I'm buying a used 636 for cheap because second gear is slipping. Gonna replace the gear myself and save a butt load of money

[@pkdann64]

Good luck. There is great satisfaction in fixing your toys.

[@einarfh]

Great video! The video is really helping me change the engine head gasket on my zx6r. Just a tip, a torque wrench should never be used to loosen bolts.

[@cesarhermosillo1420]

I nead to take my ingen apart but I am afraid of skipping a tooth on the timing my ingen is a 2006 zx6r any advice on it. Hope I get it right

[@pkdann64]

Cesar Hermosillo count the links and mark them like how they show it in the manual. That is how I did it. It is tricky but it can be done. Good luck.

[@albertomaltecca6121]

Did you succeed?

[@josephferris6936]

hey i have a 2000 zx6r the bikes are similar enough, now i see you used the tightening sequence thats in the manual to do the loosening of the camshaft cap, but in the manual from kawasaki it only mentions that pattern as a tightening sequence...is the sequence the same starting and ending position for tightening and loosening or opposite of each other? also I see the pattern for the actual head itself...should i loosen each bolt all the way then the next one or do the same pattern several times turning each nut a little bit then the next one until repeated several times and finished? one more thing... what is up with the head bolts? why is the head of those bolts have such a weird appearance and what are they called? what kind of socket for those bolts?

[@pkdann64]

Thanks for watching my video. To answer you questions, the manual does not specify sequence for loosening but I will loosen from outside to middle/inside bolts. Tightening will be from inside bolts to outside bolts. Do not loosen or tighten one bolt all the way before moving to the next bolt. Do them in increments; turning each nut a little bit then to the next and repeat several times till all are loose or torqued. This is to prevent the head or camshaft cap from warping. The head bolts have the torx design so you will need the appropriate torx socket size to remove them. I hope I answered all your question.

[@josephferris6936]

I watched your videos on youtube where you got chased by the cops good job man for being a decent citizen and cooperating with the cops... kept your demeanor good... anyway those head bolts are called dodgecagon colts and you need dodgecagon sockets to loosen them i just found out from another mechanic. they look like torx but are called dodgecagon @@pkdann64

[@dionwilliams6841]

Excellent video! Is it possible to remove the head without dropping the motor from the frame? I REALLY don't want to have to drop it to replace my cracked cylinder head. Thanks!

[@pkdann64]

Dion Williams Without trying to do it that way, I want to say yes but you could run into some clearance issue. On the same token I do not see why you can't since you don't need to drop the engine to remove the valve cover. With the proper extension and tools I believe it is possible. The head also has two bolts that hold the frame.

[@dionwilliams6841]

pkdann super! I'm going to give it a shot! Thanks!

[@mottogod]

Hello man. How do I get to contact you. I have a ZX6r I have been o working on and I need to ask some questions

[@RobertVRC]

Hey! Can you specific recompended bolt paterns?

[@pkdann64]

Robert VRC if you are talking about the head bolts, you start from the middle outwards when tightening and start from outside in when loosening.

[@sleeplikeachamp3178]

Hey bro wat model is that engine i have a 02 that im about to rebulid i was wondering can i go by ur videos to do mines

[@colin5362]

how many hours do you think you had in tear down and putting it all back together?

[@pkdann64]

For a first timer, it took me about 40 hours. I bet there are people who can do it in a day with all the proper tools and parts with you.

[@nickradakovic809]

How did u get the chain loose?

[@pkdann64]

Nick Radakovic you will need to remove the cam chain tensioner first. That will give you enough slack to pull the chain off the sprockets.

[@nickradakovic809]

pkdann I did bud thanks for these videos bro so much help

[@carlosg9934]

Hey mate what year is the engine in this video? Spotted chunks on my intake valves... First time pulling an engine off, this should be interesting

[@pkdann64]

Carlos G the engine was from a 2004 ZX6R. It should be identical to 2003 and share a few internals with other Kawasaki sport bikes. Good luck on your upcoming project.

[@thfazi1]

Having some issues with a loud knocking noise when the engine is warm after a track session, suspected connecting rod bearing failure. what was the issue with your engine? does it work now?

[@pkdann64]

Tom FZ My issue was a loud knocking sound which just showed up during a track session. I still don't know what caused it but there was some melted aluminum pieces in cylinder 4 which dented the head dome. I am running a different engine now because I used the same bad tensioner in the rebuild and jumped a tooth and destroyed cylinder 4 piston and valves.

[@thfazi1]

i am also thinking about swapping out the engine. Any checks you made to the new engine to make sure it works before installing it?

[@pkdann64]

Tom FZ The easiest way is to see and listen to it run but that's not always possible. In my case I got the engine with a badly wrecked bike but I couldn't test because the electrical cables were mangled and torn in several places. I just gambled and won on it. As for what to look for, the most important will be any damage or broken parts of the engine casing, mounting points/brackets, stripped bolt hole, and cylinder gasket leak or signs of warping. Bad valve cover gasket, oil pan gasket, stator cover gasket and water pump leaks are relatively cheaper to fix if you do the work yourself.

[@federruchi6147]

pkdann is preiginition a posibility?

[@jockbad]

Hey what year is this engine? Looks like an 04

[@pkdann64]

Yes you are right. It is an 04 ZX6R 636cc engine

[@jockbad]

pkdann sick, thanks bro!!

[@oscarsolera4765]

Gracias por el video Saludos!!!

[@TheLestad1234]

good video, but i'd highly recommend never using a torque wrench to break a bolt loose....throws off your calibration.

[@pkdann64]

Thanks, I never thought of that.

[@nickradakovic809]

I’m in the middle of doing a tear down right now lol

[@takingoutthetrash1512]

thanx for not using rap music and loud obnoxious rock...

[@aristidemercado2084]

Tengo una moto de esa 600