ZX636 A1P Carb Cleaning and Settings - ZX6R Forum
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post #1 of 16 Old 11-01-2010, 03:48 PM Thread Starter
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Unhappy ZX636 A1P Carb Cleaning and Settings

Hi,

I have lost my old password on here.. but desperatley need to clean my carb and jets... running not so smooth.

Can anyone please point me out to how to get the jets out to clean and to any required carb scress/ float setting etc.. I have had the air filter off but thats about it really!!.. will be greatly appreciated.. the bike is becomming tricky around roundabouts at low revs.. I am soon to hit the dirt!! :-)

Ta..
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post #2 of 16 Old 11-01-2010, 04:00 PM
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have you had a look in the service manual? It can be downloaded on this forum. Can't help otherwise, sorry!
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post #3 of 16 Old 11-02-2010, 09:19 AM Thread Starter
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I cant find anything in the manual i have.. I was trying to aviod buying a haynes... wondered if there was any links to carb settings and stripping etc.. had carbs balanced, cleaned air filter.. sprayed carbs... new plugs and still grumbling.. need to get jets out but not sure how easy it is...

ta
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post #4 of 16 Old 11-02-2010, 08:44 PM
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ok, its pretty easy. obviously you gotta get to the carbs. take them out (all at once). plug the intake holes in the engine with paper towels. visually clean the carbs off.

then start screwing. pretty much take every possible screw out of them. you will see a rounded plastic cap on each carb - take them off (4 screws each). carefully pull the diaphragms and needles out. next, on the other side of the carbs, take 3 screws each to take the bowls off. CAREFUL with these phillips screws - THEY STRIP. once the bowls are out you will see the floats, main jets and pilot jets. take them out. next look at the bottom hole of each carb. there should be idle mixture jets that can be adjusted. however, if you are the first one doing this, these idle jets are probably plugged with a copper washer - drill it out (dont worry its not thick. just put a thin drill in it and it will probably spin out).

This is it - you have the diaphragms/needles out, main jets, pilot jets, idle jets. now spray the hell out of them with a carb cleaner - and make sure you spray through the passages into which all these jets screw into. put it together and see what happens. replace the spark plugs too.
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post #5 of 16 Old 11-03-2010, 10:13 AM
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the zx636 is a fuel injected bike, you don't have carbs you have throttle bodies. completely different setup. i know it sounds dumb and don't be offended but are you sure you have a 636 which is a zx6r. from 03 up. before 03 the zx6r was just a reg 600.

Last edited by sportryder; 11-03-2010 at 10:16 AM.
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post #6 of 16 Old 11-03-2010, 03:16 PM
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Quote:
Originally Posted by sportryder View Post
the zx636 is a fuel injected bike, you don't have carbs you have throttle bodies. completely different setup. i know it sounds dumb and don't be offended but are you sure you have a 636 which is a zx6r. from 03 up. before 03 the zx6r was just a reg 600.
you, my friend, must read up on your kawasaki history. in 2002 they made a a1p model that had a 636cc engine
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post #7 of 16 Old 11-03-2010, 03:21 PM
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although the OP is from "north west". the 636 model was not supposed to be in US.
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post #8 of 16 Old 11-03-2010, 03:33 PM Thread Starter
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Hey Mityaz,

Thanks thats great.. I will take my time.. have plenty of carb cleaner.. and towels..!!! :-)

Sportrider - no prob for the question..now you have me thinking.... I have a 52 plate 2002.. A1-P.. I was pretty sure that it was carbs.. but it is a 636.. I know that the internet says 03 636 is injected. Maybe you are right and all 636 are injected... either way i will find out when i take it to pieces and lose some screws etc... fingers crosssed that it will run smoother when is been blasted with cleaner..

cheers
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post #9 of 16 Old 11-03-2010, 03:37 PM Thread Starter
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Quote:
Originally Posted by mityaz View Post
although the OP is from "north west". the 636 model was not supposed to be in US.
Good Point... I have done some digging and i think that you have cleared that up for me.. yeah I am from North West UK..

Thanks
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post #10 of 16 Old 11-03-2010, 04:43 PM
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Good Point... I have done some digging and i think that you have cleared that up for me.. yeah I am from North West UK..

Thanks
AHA!! So you are from Europe...

By the way, im 100% sure you have carbs my friend.
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post #11 of 16 Old 11-03-2010, 11:00 PM
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wow i had no idea. so they released the 636 a year early in europe? and released it in fuel injected form in the u.s? i stand corrected cuz i had no idea on that one. thanks for the great piece of info. let me ask you this, in 02 was the 636 body the same as the 03-04?
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post #12 of 16 Old 11-04-2010, 03:24 PM
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wow i had no idea. so they released the 636 a year early in europe? and released it in fuel injected form in the u.s? i stand corrected cuz i had no idea on that one. thanks for the great piece of info. let me ask you this, in 02 was the 636 body the same as the 03-04?
everything is exactly the same as the 2000-2002 model except for the extra 37cc's
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post #13 of 16 Old 11-05-2010, 11:10 AM Thread Starter
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Quote:
Originally Posted by mityaz View Post
everything is exactly the same as the 2000-2002 model except for the extra 37cc's
thanks guys.. I am also now well educated in the 636 stakes!!.. The fairing design changed etc.. (not sure what else).. on the 636 maybe late 2003/ 04... ( at least from the bikes I have looked at in the UK).. mine is the model where the first twin head lights came in on the 600/ 636 class.... and only appears to last a few years before the lights became thinner and meaner looking. You can prob see on my id picture (although thats the gf on the bike..) i am much taller and have a cheaper lid!! ;-)

My model was sold in green and black/ red and black / black and silver.. the new model in uk was/ is.. all blue, all black etc..

I will strip the carbs this weekend!!... and yes I am in Europe.. and the weather is awful... dark, really windy and really really wet.. welcome to England!!!!..

cheers
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post #14 of 16 Old 11-05-2010, 11:58 AM
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all the 636 600 crap is confusing to me. all i know is i have a 2009 zx6r 600cc bike. Fuel injected. nice and simple =]

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>>>>>>>>>>>>>>>>>>>>>>>6OTM September 2011<<<<<<<<<<<<<<<<<<<<<<
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post #15 of 16 Old 03-18-2017, 04:00 AM
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Hi. Just reading all this. I have a 1998 zx6r ninja g1 but it has a 2003 b1h 636 engine. Looking at all the talk mine should have fuel injection but i think its just carbs. I cannot find anything that would inject the fuel. It should have a drink system i think. So....I did not know that you could just fit carbs. Bike runs great
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