06 636 winter rebuild

[tys0n]

Sick id like to learn how to rehaul an engine someday!

[762SPR]

I put those notches in the chain because some asshat engineer at Kawasaki decided that you shouldn't be able to put on or remove the cam chain while the case halves were together! There's a little metal post under the crank sprocket that prevents the chain from being lowered off the sprocket, and I only found that out AFTER I had the whole motor built up to the head! There was no way I was going to rip it all apart again so I put those two small notches in there so I could slide it over the crank sprocket. Then once tension is put on the chain, the sides are pulled up and it can't come off.

[JohnnyP]

Originally Posted by 762SPR

I put those notches in the chain because some asshat engineer at Kawasaki decided that you shouldn't be able to put on or remove the cam chain while the case halves were together! There's a little metal post under the crank sprocket that prevents the chain from being lowered off the sprocket, and I only found that out AFTER I had the whole motor built up to the head! There was no way I was going to rip it all apart again so I put those two small notches in there so I could slide it over the crank sprocket. Then once tension is put on the chain, the sides are pulled up and it can't come off.

Oh shit thats on all the ZX6R's, sorry to hear you found out the hard way...Id be a little sketched out about milling anything off a cam chain, hopefully it doesn't affect its strength...

[762SPR]

haha, yeah I was about to be sick when I went to put it on and couldn't! I really don't think it will weaken it much, these chains have so many sections in a link and it's just a small spot out of one of them. I also have a MCCT (reminds me I gotta make sure the tension is correct!) so it shouldn't be pushing on it too hard... I'll wait for the mushroom cloud I guess, then you can all say I told you so!

Of course, now that it can come off I can always change it without separating the case halves, too! Preventative maintenance I guess.

[762SPR]

Originally Posted by tys0n

Sick id like to learn how to rehaul an engine someday!

It's really not as hard as you think. There's just a couple things you need to know, like how to properly torque things, keeping everything clean, etc. You don't really even need a manual except for getting torque values or wear limits and stuff like that. If you take it apart, it's pretty easy to know how it all goes back together. I had mine apart for a couple months and I remembered all of it even with my crap memory lol! All except that damn cam chain... There's a couple specialty tools that really help, too.

[Shane K]

DUDE!!!! that thing is sexual homie...hard to believe that's the same emo primer bike ...it looks sick man.

[762SPR]

Added some HT Moto, tailsaver, rim decals, and some direct monster injection to make my wheelies better.

[Duane S.]

Nice man

[Chadf]

Secure those front brake lines, before they grab and you fly......

Zip tie to the forks.

[Chadf]

Looks good btw.
Time to thrash her !