Engine swap

ashkan

ashkan

Banned
Hey guys,
Last year my second gear slowly went on my 06-zx636 and after talking to a few people, they all advised me to swap the engine as the labor would be more expensive to crack the block and get in the engine to fix it.
My question is, when im looking for an engine, what should i look for. How can i know if its got problems or not. Basically are there any tests or ways to tell if the engines worth buying or not? I dont wanna spend money on another engine and more money to put it in just to find out its got problems. Also, whats a good price for an 05-06 engine (roughly)
Any advised is appreciated.
Thanks..
 
Why does it have to be a Kawi?

Sent from my tablet using my paws
 
Why did you listen to those people?! I don't know what you got the spare engine for but generally in my experience I have spent around $800-1000 for 03-06 636 engines....On the flip side I rebuild their transmissions all the time for a 2nd gear slipping...If I buy new gears and shift forks its $360, but usually I can source used ones in good condition for about $100. I used to have a few but Ive used up my personal supply....Either way a rebuild from me costs about $300-$600 total....And at least you know the history of the motor, where buying used in some cases is a gamble....

I just did this 05 a while ago, I had the gears then and it was $400 installed complete! Engine out and back in the bike...
IMG_0793.jpg
 
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Damn Johnny! Thats a great deal! I'd be tempted to drop my next rebuild at your door, as opposed to doing it myself, for that kind of cost! :thumbup::thumbup:
 
I have to agree, why would anyone purchase a complete engine of unknown pedigree when it's only a gearbox problem? It's not THAT much work to split the cases, and after all the engine has to come out either way you do it.
 
I havnt bought the engine yet. Thats why i posted to get more opinions on this. I personally prefer fixing it since i really dont wanna buy a new engine i dont know the history of. in fact i found some pretty cheap engines outs there but that makes me even more skeptical. Just messaged Johnny to see if i can get a good deal/has time and hopefully ill have the bike back and not have miss any of the season. Our seasons are so short, you cant even miss a week
 
skapan said:
I have to agree, why would anyone purchase a complete engine of unknown pedigree when it's only a gearbox problem? It's not THAT much work to split the cases, and after all the engine has to come out either way you do it.
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do you know the meaning of pedigree? You make it sound like its some made in China knock off Kawi engine...
 
LoneRonin said:
do you know the meaning of pedigree? You make it sound like its some made in China knock off Kawi engine...
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It may not be a knockoff, but think about it this way, I do at least one of these trans rebuilds on 03-06 636 every season, sometimes 2-3...So imagine you bought one that also had a slipping 2nd gear...LOL You woudlnt even know it until you went through all the trouble of installing it in the bike and test riding it. Nothing worse then buying a new used engine, only to install it and find out it runs worse then the engine it replace....ughhh

Depending on how long and hard he let it slip out, will determine how much damage was done, but generally usually only have to change 2 gears and one shift fork...Its $150-160 each gear my cost and $60 for a shift fork...So under $400 cost for parts. If he can get an engine for $600ish I might go with that, but at $800-1200 Id repair what he already has...Ive done many of them....
Also a Factory pro shift kit is a good investment for those having this issue, make for more positive shifting. People I have installed it for love it!

The 09+ are where its at, the cassette transmission takes 2 hours total to swap, as it comes out through the clutch cover...The engine doesnt even have to come out of the bike...
IMG_0184-1.jpg
 
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That transmission is freaking AWESOM!!! The clutch basket goes right over that?

To the OP:
When buying a used motor, even if its a fresh rebuild, I'd do a leakdown test on it first. Very easy to do with minimal tools:
- small air compressor
- 1/4" drive ratchet
- 1/4" drive socket set
- metric allen keys
- spark plug socket
- leakdown tester

As for having your engine rebuilt, don't cheap out and get it done properly by someone who knows what they're doing. I see ZX6 motors in Johnny's shop all the time.
 
sixstring said:
That transmission is freaking AWESOM!!! The clutch basket goes right over that?

To the OP:
When buying a used motor, even if its a fresh rebuild, I'd do a leakdown test on it first. Very easy to do with minimal tools:
- small air compressor
- 1/4" drive ratchet
- 1/4" drive socket set
- metric allen keys
- spark plug socket
- leakdown tester

As for having your engine rebuilt, don't cheap out and get it done properly by someone who knows what they're doing. I see ZX6 motors in Johnny's shop all the time.
Click to expand...

Yes cassette trans, clutch cover, plates, basket, front sprocket, then a few bolts and the whole trans slides right out the clutch cover without splitting the cases or even removing the engine from the frame
 
Is this something all modern bikes have or what?

Newest bike I have is 1996 so I wouldn't know....

JohnnyP636 said:
Yes cassette trans, clutch cover, plates, basket, front sprocket, then a few bolts and the whole trans slides right out the clutch cover without splitting the cases or even removing the engine from the frame
Click to expand...
 
sixstring said:
Is this something all modern bikes have or what?

Newest bike I have is 1996 so I wouldn't know....
Click to expand...

The zx6r has it since 2009, not sure about what other brands/models have them by now, but I would think they will be like slipper clutches. Eventually all SS will have them
 
sixstring said:
Is this something all modern bikes have or what?

Newest bike I have is 1996 so I wouldn't know....
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Only some models, even today.

Cassette transmission is a Very Good Thing on a race or track bike. I've had the same race bike for years, so it's been apart a few times ... and a bust gearbox has been more common than actual engine problems. It also allows changing individual gear ratios inside the transmission rather than just changing final drive sprockets, which can be a compromise - and you can do it at the track. If you are having a particular issue with being between gears on a particular corner, you can change specific gear ratios to fix it.
 
sixstring said:
That transmission is freaking AWESOM!!! The clutch basket goes right over that?

To the OP:
When buying a used motor, even if its a fresh rebuild, I'd do a leakdown test on it first. Very easy to do with minimal tools:
- small air compressor
- 1/4" drive ratchet
- 1/4" drive socket set
- metric allen keys
- spark plug socket
- leakdown tester

As for having your engine rebuilt, don't cheap out and get it done properly by someone who knows what they're doing. I see ZX6 motors in Johnny's shop all the time.
Click to expand...
Thanks for the details buddy! ill def keep that in mind if i end up swapping but im gonna try to get it rebuilt since i know the history of the engine. Seems like buying a new used engine can be risky
 
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