New Owner in SD - ZX6R Forum
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post #1 of 15 Old 02-19-2017, 10:00 PM Thread Starter
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New Owner in SD

Hey everyone,

Name: Grant
Bike I bought today: 2003 ZX-6R
Location: Rapid City, SD (the place with the 4 presidents made out of rock)

So far I am really happy with it! The 636 is a little outside of my comfort zone coming from about one year of experience on a Suzuki DRZ400S which I loved but did not fit (I am a bit vertically challenged at 5' 8") but being outside the comfort zone is where you learn the most

I am happy to see there is an active forum for the bike and am looking forward to learning from all of you!

Outside of the motorcycle hobby, I am pursuing a mechanical engineering degree and lead a Formula SAE Team on the SD Mines campus.
What is Formula SAE? -> www.HardRockerRacing.com (We build a small-ish racecar for autocross).
In high school, I competed in "Skills USA" doing the motorcycle technician competition and learned a lot from my shop teacher about bikes!

Thanks and feel free to send questions my way!
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post #2 of 15 Old 02-19-2017, 10:25 PM Thread Starter
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Doing a bit of looking around, I am already finding lots of helpful content!

This basic maintenance thread will probably come in handy. I have done plenty of this basic stuff, but it never hurts to do a quick review! - FAQ: Basic Maintenance

The service manual was super easy to find! - http://support.bazzaz.net/service_ma...ZX636B1_B2.pdf

List of stuff to do ASAP:
-Tighten up the right footpeg, it felt a little wiggly with weight on it
-Check/change the air filter
-Oil & filter change (believe it was changed June '16)
-Check chain tension (hoping the service manual gives me numbers on how much variance is allowed and if it needs to be changed)
-Replace spark plugs
-Lube up cables
-Check/change coolant

Further down the road stuff:
-Fork rebuild (front right fork has a bit of oil)
-Rear fender (not sure if I should change it or just add blinkers DIY)

I would happily take feedback from anyone and look forward to the coming projects and riding!
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post #3 of 15 Old 02-20-2017, 01:44 AM
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Welcome aboard man!

U seem to know what youre doin
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post #4 of 15 Old 02-20-2017, 03:01 AM
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Welcome. Glad to hear you are actively gathering data so you can make good decisions on what to do when.

Chain tension..... better to be a bit too loose, than too tight.

If the fork is weeping, the seals have failed. Move this one up your list of Things To Do.

Triage based on consequences.... first order of business is to make sure it will stop when you need it to, which is right after you wanted it to. fluid, then pads, then lines, then MC and calipers.

Tires...... if they are more than 5 years old, budget for new skins as soon as you can afford them.

"Basic stuff fellas. Use your head for something other than to break your next fall."

"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #5 of 15 Old 02-20-2017, 06:07 AM
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Quote:
Originally Posted by grantmines View Post
Doing a bit of looking around, I am already finding lots of helpful content!

This basic maintenance thread will probably come in handy. I have done plenty of this basic stuff, but it never hurts to do a quick review! - FAQ: Basic Maintenance

The service manual was super easy to find! - http://support.bazzaz.net/service_ma...ZX636B1_B2.pdf

List of stuff to do ASAP:
-Tighten up the right footpeg, it felt a little wiggly with weight on it
-Check/change the air filter
-Oil & filter change (believe it was changed June '16)
-Check chain tension (hoping the service manual gives me numbers on how much variance is allowed and if it needs to be changed)
-Replace spark plugs
-Lube up cables
-Check/change coolant

Further down the road stuff:
-Fork rebuild (front right fork has a bit of oil)
-Rear fender (not sure if I should change it or just add blinkers DIY)

I would happily take feedback from anyone and look forward to the coming projects and riding!
Hello and welcome!

From your to-do list:
  • When you check the air filter, find out if it is an aftermarket filter that can just be cleaned and re-oiled (e.g. K&N, BMC, etc).
  • For oil and filter, I use and recommend Shell Rotella T6 and Purolator PureONE PL14612 or PL14610 (whichever one will fit best lengthwise).
  • Yes, the service manual will give you the specifications for proper chain tension.

Winner - 6OTM - March 2014
2009 ZX-6R (65,695 miles and counting) | www.ZX6R.us | www.Seaton007.com

M4 GP Slip-on | ASV C5 Levers | Spiegler SS Brake Lines | SpeedoHealer V4
Custom FE | K&N Air Filter | Vortex Sprockets -1/+2 | EK MVXZ Chain

Last edited by Strider; 02-23-2017 at 01:43 PM.
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post #6 of 15 Old 02-20-2017, 03:33 PM
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Welcome to the forum.

Sounds like your are young,
Find a track day organization, and have fun. You will be able to push it in a safe controlled environment. Might take one or two days to find the limits of your bike. LOL.
Wish they were around way back when.
Of course pictures are nice.
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post #7 of 15 Old 02-20-2017, 10:00 PM Thread Starter
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I certainly like the idea of doing some track days! I will be in Kanasas City this summer and so will be closer to some tracks than Rapid City is, so hopefully.

So a bit of an update after the first day:

-LED headlight flickered on and off, turned out to be a connecter that jiggled loose, easy fix and will check on it from time to time

-realized that a windscreen will be necessary for any higher speeds

-checked the air filter and it is a k&n which is clean and appears to have oil left on it

-pegs were a tad loose and took about 5 mins go get fixed up

-peeled off the poorly done plastidip on the tail, will probably be redone soon

-looking at purchasing ebc sintered pads from moto superstore, I would appreciate advice here! They seem spendy to me, but brakes are pretty important

-Planning to buy frame sliders, amber led strips, wire, and resistors off of Amazon

-need to figure out the front fork seal issue ASAP, no idea on this process yet, so I will be digging around the forum for that info!

-want to get oil and filter and spark plugs changed soon as well so I know that stuff is fresh. Would be nice to do the same with coolant but will probably decide based on how dirty it is

-my memory of adjusting chains tells me it should be fine, but should double check soon with a ruler and the manual since i have no idea how old the chain is.

Attached are some pictures I took tonight in Art Alley in downtown Rapid City.

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post #8 of 15 Old 02-20-2017, 10:17 PM
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Quote:
Originally Posted by grantmines View Post
I certainly like the idea of doing some track days! I will be in Kanasas City this summer and so will be closer to some tracks than Rapid City is, so hopefully.

So a bit of an update after the first day:

-LED headlight flickered on and off, turned out to be a connecter that jiggled loose, easy fix and will check on it from time to time

-realized that a windscreen will be necessary for any higher speeds

-checked the air filter and it is a k&n which is clean and appears to have oil left on it

-pegs were a tad loose and took about 5 mins go get fixed up

-peeled off the poorly done plastidip on the tail, will probably be redone soon

-looking at purchasing ebc sintered pads from moto superstore, I would appreciate advice here! They seem spendy to me, but brakes are pretty important

-Planning to buy frame sliders, amber led strips, wire, and resistors off of Amazon

-need to figure out the front fork seal issue ASAP, no idea on this process yet, so I will be digging around the forum for that info!

-want to get oil and filter and spark plugs changed soon as well so I know that stuff is fresh. Would be nice to do the same with coolant but will probably decide based on how dirty it is

-my memory of adjusting chains tells me it should be fine, but should double check soon with a ruler and the manual since i have no idea how old the chain is.

Attached are some pictures I took tonight in Art Alley in downtown Rapid City.
The EBC sintered brake pads are great. I use the EBC HH pads on the street and track. The whole set may be a bit less expensive here: EBC HH Front & Rear Brake Pads Set - Kawasaki ZX6R / ZX6RR - 2003-2006 _FA369/4HH|FA192HH
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Winner - 6OTM - March 2014
2009 ZX-6R (65,695 miles and counting) | www.ZX6R.us | www.Seaton007.com

M4 GP Slip-on | ASV C5 Levers | Spiegler SS Brake Lines | SpeedoHealer V4
Custom FE | K&N Air Filter | Vortex Sprockets -1/+2 | EK MVXZ Chain

Last edited by Strider; 02-23-2017 at 01:38 PM.
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post #9 of 15 Old 02-21-2017, 08:08 AM Thread Starter
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Uh oh, went to go start it this morning to ride to school and it won't fire. It would turn over and sounded pretty healthy but not even once did it fire.

The tail pipe smells a little bit of rich fuel so I think it was injecting fuel but it is very hard to tell. Last night it seemed to be running perfect.

The Fuel Injection light lit up a couple times during cranking and the oil light stayed on the whole time. Is it a shared oil? Because the sight glass shows plenty of oil.

Also, the display flashed while cranking like the voltage might be dropping too low or something. Checked the voltage at the battery:
-bike off: 11.07v
-bike turned to on position: 10.31v
-cranking: 6v

I am thinking bad battery


Help!

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Last edited by grantmines; 02-21-2017 at 08:17 AM.
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post #10 of 15 Old 02-21-2017, 08:21 AM
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Yup, sounds like a bad battery. Try bumpstarting it.
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post #11 of 15 Old 02-21-2017, 12:58 PM Thread Starter
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The battery was too low to get the bike started, I assume not enough for spark and that is why it wouldn't fire.

I borrowed my roommates jump pack (about the size of an Ipad) and got it started on the first try. That was a relief.

I had the led headlight on for about 45 minutes last night while working on the bike in our unlit shed, so that probably drained the battery enough to cause these issues.

Then again, I am not sure how old the battery is, no date on it, so I pulled the battery out of the bike and have it on a charger currently. I might bring it into Interstate Battery and have them do a draw test because I don't want to get stuck in the middle of nowhere with a bike that won't start.

Would it be a better idea for me to turn this thread into a build thread rather than in the new owner area?
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post #12 of 15 Old 02-23-2017, 09:54 PM Thread Starter
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Progress Update

Parts are arriving! I have the new brake pads and should be getting a few other goodies soon.

Onto the Fork Seal Replacement Research:
Tools/supplies I am gonna need:
-2 Oil Seals (Kawi #92049-001)
-2 Dust Seals (Kawi #92093-1472)
-Fork Oil (SAE 10) (2 quarts)
-Spring Compressors (can be homemade)
-Giant Allen Tool (~19mm) - the back of a spark plug socket may work
-Wrenches (14mm among others)
-Digital Caliper
-Long nut and bolt
-30mm socket
-bearing press object (huge socket)
I am gonna get all the tools and parts together that I will need and go from there! Thank you to "The Amp Lab" on YouTube for the helpful video.

The pictures show the shed that I am doing this work in where me and my buddy's bikes are parked, the removal of my rear tire for replacement, and the diablo 190/50 that the PO included with the bike.
-He told me that he thinks the tire has a slow leak in it, so right now, I am thinking it isn't even worth paying to get it mounted and that I should just scrap it. That idea is a little painful knowing that it is a $100+ tire, but it was made in 2008, so that is probably what's best.
Yesterday I was riding the bike, today it is snowing! Gotta love South Dakota!

So the to-do list right now includes:
-New Rear Tire
-Paint rear rim black
-New Fork seals
-New brake pads
-Oil Change
-Coolant Flush
-New Spark Plugs
-Lube up cables
-Check chain for tension/wear
-Put on frame sliders
-Wire in led headlight to original relay
-Wire in new led blinkers as original
-Possibly do black exhaust wrap

Oh ya, and I should probably take the time to do a thorough wash of the bike

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post #13 of 15 Old 03-03-2017, 03:07 AM Thread Starter
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So the work took a short break during my homework filled week and now I am back to working on the bike.

-I got an awesome front stand from PitBull, it is very well made and sturdy ($190)
-I got the brake pads replaced front and rear ($141)
-The rear caliper was a real PITA!
-I have gold wheel paint I plan to apply this afternoon ($30)
-I got Metzler M7 RR tires front and rear from Rocky Mountain ATV, which should go on tomorrow once wheels are finished ($230)

We should be having 60 degree weather for a few days in the next week, so I want to get it going ASAP! That is good motivation!


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post #14 of 15 Old 03-03-2017, 03:21 AM
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Try to get the wheels powdercoated instead of painted. It would make it a lot easier to clean.
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post #15 of 15 Old 03-03-2017, 05:01 AM Thread Starter
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Quote:
Originally Posted by Scorpi0 View Post
Try to get the wheels powdercoated instead of painted. It would make it a lot easier to clean.
Only problem is cost. I called my local powder coating guy and he wants $125 per wheel for blast and coat. Maybe if I am dissapointed with the paint I will fork up the cash for powder coating, but right now I am just spending so much on everything else.

$30 for paint versus $250 for powder 🙄
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