new member starts with questions - ZX6R Forum
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post #1 of 11 Old 04-14-2017, 10:24 AM Thread Starter
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new member starts with questions

hi there.
a new owner from brooklyn, ny is checking in. this isn't my first bike but fist sport bike. i always wanted to have one and finally decided to pull the plug last month. bought a used one off ebay, 20,000 miles '06 XZ6R, green.






Albeit low mileage the bike appears to be neglected, rusty drive chain, missing screws all around the fairing. Some screws overtighten with stripped well nuts threads. It was such a PITA getting them out. Right side tank screw missing... seriously?!?!?!?!?!. Missing dowel from camshaft cover.
The bike seems be lowered too, so the second order of business would be bring it to the stock heights.
What's the first order?, well that's where my question begins.
Seeing how neglected the bike was I decided to check valve clearance. Downloaded service manual from the web and was immediately puzzled.
The page 2-26 says #1 piston TDC is when IN mark of intake shaft faces opposite direction of EX mark of exhaust shaft. My problem is that at this position of the shafts noses are still on the valves, i cannot insert any size of feeler through under #1 lobes. But I can on #4 cylinder. So, I wonder what am I doing wrong? Is this possible that in '06 service manual they messed up #1 and#4 TDC positions?

Incidentally (no really), I downloaded 07 service manual. There, on page 2-21 the camshaft positions are drawn opposite to '06 manual, and actually make sense.

Please help and explain this conundrum.
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post #2 of 11 Old 04-14-2017, 11:10 AM
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It is possible they're incorrectly written. Like, maybe 05 they were like that, manual didn't get updated, but there's an addendum out there for the change.

That kind of thing can happen. I'd verify it's not literally assembled backwards, but past that, doing what obviously looks correct probably is.
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post #3 of 11 Old 04-14-2017, 11:46 AM
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post #4 of 11 Old 04-14-2017, 02:21 PM
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Quote:
Originally Posted by commiehunter View Post
It is possible they're incorrectly written. Like, maybe 05 they were like that, manual didn't get updated, but there's an addendum out there for the change.

That kind of thing can happen. I'd verify it's not literally assembled backwards, but past that, doing what obviously looks correct probably is.
My 06 I had the same problem. If your on 1/4 look at the valve clearance checks.
You will find OR at least I did, 1/4 was for both sides.
I could get half, at 1/4 rotate one revolution to 1/4 and did the other half.
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post #5 of 11 Old 04-14-2017, 02:51 PM
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Quote:
Originally Posted by Indy View Post
My 06 I had the same problem. If your on 1/4 look at the valve clearance checks.
You will find OR at least I did, 1/4 was for both sides.
I could get half, at 1/4 rotate one revolution to 1/4 and did the other half.
Maybe goblin will, but I'm not following what you're suggesting here. Care to elaborate? I'll be doing my valve clearance check in the next month or so and would love to know more about a potential problem before getting to it

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post #6 of 11 Old 04-14-2017, 05:03 PM
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Originally Posted by NitrusReigns View Post
Maybe goblin will, but I'm not following what you're suggesting here. Care to elaborate? I'll be doing my valve clearance check in the next month or so and would love to know more about a potential problem before getting to it
OK,,, if you read the page and don't assume like I did..
The basically say, when doing TDC 1 check these valves.
When doing TDC 4 do these valves..

I ASSUMED I would put the crank at 1/4 measure those valves then rotate it to 2/3 and measure the rest. Never measured one valve using 2/3.

What I'm trying to say. IF you move crank to 1/4, look at the valves. You will either be doing the TDC 1 or the TDC 4. Both will have the crank at 1/4 IF at one, then rotate the crank until your at the other.

I'm attaching just those pages.
Attached Files
File Type: pdf Ninja ZX-6R ZX636C1_C6 valve check.pdf (1.41 MB, 7 views)
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post #7 of 11 Old 04-15-2017, 12:49 PM Thread Starter
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Crank shows correct markings; there are two 1/4 and 2/3. This is because full cycle of the engine equals 2 revolutions of the crank.
In other words, when 1/4 marking in correct position either cylinder #1 or #4 at TDC. Rotating the crank 360 degree will reverse TDC of #1 and #4 cylinders. The question is which ones.
So, on the page 2-26 it clarifies that when markings on the cam shafts are as follows
<-IN EX->
This means #1 TDC.

When markings are
IN-> <-EX
This means #4 TDC.

And that's where I became confused, 'cuz <-IN EX-> brings #4 to TDC, not #1 as the Manual states. And vice versa IN-> <-EX in spite of the Manual is actually #1 TDC.

I've googeled 2006 service manual pdf, found a couple of more revisions yet all of them show incorrect markings. Assuming they are incorrect and I am not going crazy.
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post #8 of 11 Old 04-15-2017, 03:49 PM Thread Starter
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Originally Posted by commiehunter View Post
It is possible they're incorrectly written. Like, maybe 05 they were like that, manual didn't get updated, but there's an addendum out there for the change.

That kind of thing can happen. I'd verify it's not literally assembled backwards, but past that, doing what obviously looks correct probably is.
im following what you said. i've checked everything else, and it's either the manual is incorrect or im loosing my mind. i reject the latter.
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post #9 of 11 Old 04-15-2017, 05:57 PM
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Originally Posted by goblin View Post
im following what you said. i've checked everything else, and it's either the manual is incorrect or im loosing my mind. i reject the latter.
LOL..

For valve checks, to heck with the cam markings. Just look and see which cylinder set allows you to do both intake and exhaust.
Using there chart you know what other ones should be good to check.

Rotate the crank 360, it will be the other example in manual.
The cam marks for me only came into play when they had to come out.
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post #10 of 11 Old 04-15-2017, 06:35 PM Thread Starter
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Quote:
Originally Posted by Indy View Post
LOL..

For valve checks, to heck with the cam markings. Just look and see which cylinder set allows you to do both intake and exhaust.
Using there chart you know what other ones should be good to check.

Rotate the crank 360, it will be the other example in manual.
The cam marks for me only came into play when they had to come out.
For the valve check, yes, I agree no need to check the markings.
Markings became important the moment I started putting chains back on the cams after replacing the shims. And this is where the roots for the confusion where.
On page 5-18 of camshaft installation it describes #4 TDC by markings <-IN EX->.
On page 2-26 the same marks <-IN EX-> say it's #1 TDC.
Nuts.
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post #11 of 11 Old 04-23-2017, 08:29 AM Thread Starter
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For those who are interested. I finished valve clearance adjustment, had to replace only one shim. Put the bike back together, started up no issues.
So, I guess it's official - there is a typo on page 2-26 of 2005-06 service manual, the pictures reversed #1 and #4 TDC
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