Head gasket

[StuMiller]

I'm going to have a crack at changing the head gasket on my 99 ZX6 track bike, then sell it.

How hard are they to do?

Any advise is appreciated, besides, what's the worst that can happen...

[oldman]

I have never changed a head gasket on your particular bike, but they are not rocket science. Make sure you have a manual to tell you what position the crankshaft has to be in to avoid bending valves on reasembly as well as torgue specs and cam chain position. Mark your cam chain position on the chain and the sprockets to avoid any major screwups then double check them, (according to the service manual) to make sure they are correct. Remove the cam chain from the cam shafts. You can leave the cams in place as long as the head is true, unless as on some bikes the cams are in the way of a head bolt. If the head has to be shaved then the cams will have to be removed. If the cams have to be removed read the instructions in the service manual carefully as a fuckup here could ruin the whole process. Check your head for cracks, (best done by a cerified mechanic) also have the head and block surface checked for being true, (meaning flat not warped). make sure the head and block surface are completely clean. then carefully place the head gasket then the head on the block. Then follow the bolt pattern tightening sequence to retighten the head bolts. Do not tighten them to full torque specs on the first try, go a little at a time following the tightening sequnce until you have them at the proper torgue, (at least 3 or 4 tightenig sequenses). replace the camshafts, if removed, then the cam chain, (double check the cam chain sprocket to crankshaft sprocket position as a mistake here can ruin your day) Check your valve clearances as they have probably changed and adjust accordingly. I don't think I've forgotten anything but who knows, good luck. Oh! wait! Jim Beam is a fantastic mechanics tool.

[Jonno]

Oh! wait! Jim Beam is a fantastic mechanics tool.

Nice explaination Paul

[JonW]

One more tip.
Leaving the plugs out, you should be able to turn the motor over with a 6" shifter. If you cant, something is amiss.
Probably cam/valve timing.

Now at this point, kick dog, swear at wife/significant other, break open another beveridge then sit down and do it again, this time get it right...

[budgienutz]

You could give the bike to me,ill fix it and use it as a track bike

[kghost]

I've never worked on that model either just a couple notes:

Careful what you scrape old gasket material off with....steel on aluminium is not generally a good idea.
Some green nylon (scotch, 3M etc) scouring pads work wonders.

Watch the position of dowels and o-rings when you remove the head.
You'll wanna know where they go on reassembly. Missing an o-ring on an oil passage can suck.