First Service Assistance Staff
by Staff
I have a question for all you MOfo's out there. I recently purchased a new 2003 Kawasaki ZX6R and I was wondering what all is included in the first service (600 mile) service? Also as somebody with moderate ability with a wrench could I do this procedure my self, and if so what kind of equipment will I need aside from the normal sockets, wrenches, and allen wrenches?

The major things of what they're supposed to do is change all the engine's oil(s) and check for metal or other nasties, and check the valves to see if they need adjusting. Doing it yourself isn't hard, but likely will void your warranty...

Surprisingly, modern-day valves rarely need adjusting, but the initial service can be the exception to that rule. It's not very hard, basically (after getting the rockerbox cover off, which can be a pain!) you turn the cam to point away from the top of the valve and measure the maximum clearance. Write it down. Do so for each cylinder. If any are out of alignment, remove the cams and take the bucket off the top of the valve. There's a shim underneath, mic it, subtract the difference that it's out of adjustment (valves usually recede into the head, if you've got one that's moving down towards the piston, that's bad and you probably are losing a seat or have something stuck in there!) and presto! You have the size of the shim you need. Go to the dealer and buy a new one in the right size for each out-of-adjustment cylinder, and put it all back together. Comparmentalized sewing boxes really help to keep everything in order when apart. Label them by cylinder number, intake/exhaust and left/right valve. Left on the bike is always left as you're sitting on it, not facing it. Magnetic Snap-On work trays are good for this, too.

Cheapos can look to see if you can swap shims around if you have several valves out of adjustment, but if you're going to do your own work, it's best to buy new shims and then you start, by default, getting a collection of shim sizes. Keeping them all separated in sewing boxes with labels above their comparment telling their thickness is the way to go, and makes you look like a pro!

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