36,000k major service

Well don't I feel proud. Just completed a major service on the 636. Clearances, balance, liquids, filters, and a general grease up.

Wasn't much of an issue at all, and to all those guys out there thinking of doing clearances themselves I'd recommend it, just read up on it first!

As I said before Peter Stevens in the City are tools, and have been setting the exhaust clearances too tight. Now thats all fixed with a nice eventful ride out to Croydon to see Chris at Precision Shims. Turns out he's just a backyardy and wasn't at home when I popped over. So after lunch I thought a nice flick through the black spur would be the go. Lets just say the old mans GSXF is certainly a gaint leap back from the 636. It had just finished raining on the spur and the sun was out, absolutely beautiful cruising through with the steam rising, if only I had the camera.........
On the way home I discovered my attempt at re-waterproofing my oversuit hadn't worked, in a big way.

Anyways now all the clearances are within spec. Setting the cam chain again was a peice of cake (well almost, kept wanting to give itself slack between the two cams) and I only heard a click or three as the tensioner picked up the slack, so I'm guessing it hasn't streched a whole lot yet.

Carbs were barely out at all, but I did find we had a spider living in one of the balancer tubes stopped the vacuum nicely, lets just say he wasn't so pretty after a dose of compressed air.

Now everything is back together and running like a dream. Took me 4 or so days only working on it a couple of hours a day (I wasn't in a rush).

Attachments

Starting off

beginning.jpg (37.09 KiB) Viewed 2016 times

carbs off

middle.jpg (37.47 KiB) Viewed 2015 times

Cams out

cams-out.jpg (32.63 KiB) Viewed 2013 times

This is what I need to do to mine... DESPERATELY...

I think with funds being tight, I might have to call on Rossi, Strika and whoever else for assistance down the DIY path..

Hope to see you on a ride soon.

Set me back $200 Dan

$50 Motul 5100
$150 for
- Valve cover gasket
- Timing cover gasket
- 4 plugs
- 4 plug gaskets
- Genuine oil filter

($44 of that was the spark plug gaskets in the valve cover which you could definitely skip, and I forgot to mention the magic password at Bkwaka)

Oh and plus $44 for 8 shims

And you can count me in for a hand too

cheap as.

i paid $340 for my 36000 major service, that included bearings front and back.

- Valve cover gasket

Reusable, just make sure you clean both it and the mating surfaces on the head and the cam cover.

- Timing cover gasket

Reusable with a bit of gasket goop.
(annoyingly enough, the ZX9 runs a rubber O-ring as the seal for the timing cover, but the ZX6 doesn't)

- 4 plug gaskets

Totally reusable.

Oh and plus $44 for 8 shims

Next time, dude, call Precision Shims Australia (he's in the phonebook) and leave him a message; $5.50 per shim, overnight delivery.

I have to do my shims.

Is there any special tool required ?

I have to do my shims.

Is there any special tool required ?

Set of feeler gauges; $6 from Bunnings.

Low-range beam-deflection torque wrench; $230 or so from a specialty tool shop.

- Valve cover gasket

Reusable, just make sure you clean both it and the mating surfaces on the head and the cam cover.

Mine was cracked and leaking

- Timing cover gasket

Reusable with a bit of gasket goop.
(annoyingly enough, the ZX9 runs a rubber O-ring as the seal for the timing cover, but the ZX6 doesn't)

again mine cracked on removal, but your right you could get away with these things on the cheap

- 4 plug gaskets

Totally reusable.

Oh and plus $44 for 8 shims

Next time, dude, call Precision Shims Australia (he's in the phonebook) and leave him a message; $5.50 per shim, overnight delivery.

Ahhh dude I did, I picked them up from his place in Croydon