HOW TO: change spark plugs 06 636 - KawiForums - Kawasaki Motorcycle Forums
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 26 (permalink) Old 05-09-2009, 10:31 AM Thread Starter
Jr. Member
 
vbroom's Avatar
 
Join Date: Jul 2008
Location: Perth, Australia
Posts: 120
          
Send a message via MSN to vbroom
HOW TO: change spark plugs 06 636

k, time for me to do a service so thought i might do a write up with pics for you guys.

1. take side panels and seat off (no pics for this. if you don't know how to do this...i'd recomment NOT doing this job yourself and getting a mechanic to change your plugs....)

2. remove tank. There are four bolts you need to unscrew to get the tank off,
1 at the headstem of the frame, 1 under the seat and two on the sides in the middle of the frame. No pics for this....pretty self explanatory.


3. to completely remove the tank you need to disconnect 3 hoses/clamps.


unclip this clamp at the bottom of your tank. before you do so, you might want to throw a rag under it to catch the bit of fuel that might leak out. yes they are old undies. shut the fuck up.






unclip this electramickle clip under your seat.

there is also a small hose under the tank on the left hand side (as you sit on the bike) that you need to unplug.

4. now you have access to the air filter housing. (which you need to remove) to do this there are 5 bolts you need to unscrew.

first is at the top near the headstem.


the rest are under the airbox and are the housing clamps (there are 4 of them)

5. next you have to disconnect the injector clips at the top of the airbox. There are five clips in total. (4 black for each injector and 1 green at the end)

6. next there are four hoses you have to disconnect.

first is on the left hand side (as you sit on the bike)

next is the big hose at the bottom of the airbox in the center

next is the fuel clip under the big house you just disconnected

and lastly is the hose on the right hand side under the airbox


7.
the airbox can be completely removed now. Take the chance now to give it a wipe down because it'll probably be dusty and full of bugs.

8. you should now be able to see the 4 coils. unplug each of the electrical clips to them


9.
now prepare yourself for some serious cursing and hard work. you have to pull each of the coils straight up and out. giving them a bit of a wiggle or an unscrewing action may help abit...but you need constant force pulling upwards.
good luck getting the last one on the left off....the frame gets in the way and causes many profanities to be thrown around.

10. now you can relax because thats the hardest part. All thats left is to get your spark plug socket tool and unscrew the old plug out and screw the new plug in.

once again, the very left one will give you troubles because there is very little clearance to get your spark plug socket and handle in there.

I made a visit to the local auto store and found this beaty. A flexi 1/2" drive extension. Made the last plug a breeze to get in and out.



And that's it. You're done. Assemble everything back, and double check you've reconnected every hose, screwed back every screw and clipped every clip back.

i accept no responsibility for anything you do to your bike. This is just a guide. If you are not sure on how to do anything after reading this and consulting your service manual and read through the wealth of information on this forum, i'd suggest not attempting it yourself.

Having said that, go forth and changeth thy plugs!
vbroom is offline  
Sponsored Links
Advertisement
 
post #2 of 26 (permalink) Old 05-09-2009, 10:49 AM
Jr. Member
 
Join Date: Nov 2007
Location: Long Island, New York, United States.
Posts: 110
 
nice write up, yea pulling those coils is a SERIOUS pain in the ass especially the last one on the left
jtrabold is offline  
post #3 of 26 (permalink) Old 05-09-2009, 10:42 PM
GTS
Jr. Member
 
GTS's Avatar
 
Join Date: Aug 2008
Posts: 111
       
yup, the left is a pain in the a$s, just did this last week, great write-up!

Almost complete...
GTS is offline  
post #4 of 26 (permalink) Old 05-10-2009, 06:48 AM
Member
 
Join Date: Feb 2009
Posts: 443
           
You don't have to remove the airbox, you can just unhook the hose at the front and fold it over towards the back of the bike giving you plenty of room to access the spark plugs and less stuff to put back together :].

I wish I had one of those flexible extensions :[
zoink is offline  
post #5 of 26 (permalink) Old 05-10-2009, 04:16 PM
Member
 
Join Date: Jan 2009
Posts: 415
   
Also, I would put a paper towel or cloth to cover your throttle bodies to prevent any unwanted material from getting in there. You could also clean them while you're there if they are dirty. Use throttle body cleaner.
Good write up and excellent pics! I need to do this soon too.

2006 Kawasaki Ninja ZX636R

Last edited by crzy88; 05-10-2009 at 04:18 PM.
crzy88 is offline  
post #6 of 26 (permalink) Old 05-19-2009, 10:30 AM
Jr. Member
 
Join Date: Aug 2006
Location: Fort Worth, Texas, United States.
Posts: 98
 
How many miles had you rode and what shape were the original plugs in?
thanks
SIRpent is offline  
post #7 of 26 (permalink) Old 05-19-2009, 02:01 PM
Intermediate Member
 
kaoss_11's Avatar
 
Join Date: Apr 2009
Location: SOCAL
Posts: 2,544
           
u should have done the kleen mod while you had everything apart
kaoss_11 is offline  
post #8 of 26 (permalink) Old 05-21-2009, 10:54 PM
Member
 
Join Date: Jan 2009
Posts: 415
   
Quote:
Originally Posted by SIRpent View Post
How many miles had you rode and what shape were the original plugs in?
thanks

I would follow your manual for when to do it. For me it says at 7500, 15000, 24000, 30000.

Nice use of undies btw vbroom

2006 Kawasaki Ninja ZX636R
crzy88 is offline  
post #9 of 26 (permalink) Old 05-22-2009, 01:48 AM Thread Starter
Jr. Member
 
vbroom's Avatar
 
Join Date: Jul 2008
Location: Perth, Australia
Posts: 120
          
Send a message via MSN to vbroom
bike was at 22,000 k's whatever that is in miles

yeah i follow the manual for when to change.
vbroom is offline  
post #10 of 26 (permalink) Old 07-17-2009, 01:05 AM
Lifetime Premium
 
ZX6RRNewbie's Avatar
 
Join Date: May 2004
Posts: 15,931
           
Why do you have to "unclip this electramickle clip under your seat."???
ZX6RRNewbie is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the KawiForums - Kawasaki Motorcycle Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome