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How To: 1st service for 04' ZX636

elskipador

elskipador

elskipador@gmail.com
Joined
Feb 22, 2003
Location
gilroy
Moto(s)
the trickest f2 you've ever seen.
Name
shawn
so this pictorial is about how to provide the 1st service for your brand new, shiney, pretty bike. the ridz an 04 ZX636 with 664 miles on it. i did a lot to this bike and only found a couple of things not quite right. pretty good with all the recent trouble with loose bolts and fucked up shit coming out of factory shops. the kawasaki manuals says we should check/inspect/replace these items.

throttle control system
idle speed
evap system
cooling hose connections
clutch adjustment
oil
oil filter
chain slack
brake switch operation
brake hose connections
streering-inspect
nuts,bolts and fasteners tightness-inspect.

i did all this plus a plug change and throttle body sync. took me a little bit over 3 hours total, from start to finish. enjoy :staRang
 
bike, 04 ZX636

1360735-dsc00780.jpg
 
loosen the fairing bolts and clips and remove the lowers

1360736-dsc00781.jpg
 
start by removing the oil filter drain plug and sealing washer

1360740-dsc00783.jpg
 
the oil looked really clean. we used a non-sythn petro oil for the refill

1360742-dsc00784.jpg
 
remove the filler plug to help with draining

1360744-dsc00785.jpg
 
next loosen the oil-filter retaining clamp. this thing it great, keeps your filter clamped on, just like a race bike. its about time the factory started doing this. maybe frame sliders will come out on factory bikes soon :love

1360746-dsc00786.jpg
 
remove the clamp and filter. it takes a 64mm filter wrench

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apply a thin film of oil to the new filter and install it. torque to 31 N/m

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fill the motor back up with 4.0L/4.2 qt of oil

1360751-dsc00814.jpg
 
now that the oils done we can start checking torques on lots of critical bolts. upper moto mounts 1st. 44 n/M

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you'll need this special tool to check the torque on a couple bolts

1360758-dsc00788.jpg
 
lower rear engine mounting lock-nuts. 49 N/m

1360763-dsc00793.jpg
 
upper rear engine mounting lock-nut, also 49 N/m

1360764-dsc00794.jpg
 
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