Stole Phr3ek's 636, innards pics

[ninja250]

Finally got my hands on Kevin's rattling 636 with every upgrade in the world on it.

Love this bike! Learning to do I4 valves on this machine. So far, just as easy as the Ninjette but twice as many valves! They look to me smaller valves and closer together too. I would call that higher performance than the ninja. lol

You can see, 10 of the bike's 16 valves are out of spec!

I have to pull the cam covers off now and pull the cams and CCT and get to the shims so I can measure them, then do math to figure out what shims to put back in. Simple as pie.

You guys have 600's that need VJ's now, bring them in too!
More pics to follow. I'll know what shims we need to order for Kevin's 636 tonight. He'll be back up and running soon.

[ninja250]

Yummy.

I found out the shims from the 636 are the same size as the shims from our Ninjette.

Kevin is in luck. He will have his bike back 7 times faster than originally anticipated.

Wish our 250 had one of these instead of the one it has!


I think these are extras. We can throw this away.




DOHC under the bike


SOhandC


Green oil? Pink coolant?


Busy garage at break time.


This is how I decided to prop the chain.


Yank the shims out from under the buckets and fill in the blanks.




Oh snap, now we know what to put back in the bike!


Another night in paradise.

[Cazper]

Wow that process and paperwork look strangely familiar!!! Glad to know that things are going smoothly on "good Kevin's" bike...lol. I also notice that much like our little ninjette's the exhaust seems to go out of spec more so than the intake... interesting note.

I'm sure his bike will run much better after this!!!

[phr3ek]

damn, look at that nice, clean green oil
i kinda wish i didnt do the oil change earlier....
if only i could recycle that fairly fresh used oil

meow

dexcool is weird
its looks pink but pours orange

[ninja250]

The only oil pan I have is contaminated. Sorry dude, when I drop oil, it has to go. =(

I buttoned your engine back up just now and spun the crank and remeasured. All seams good!
If something would have went wrong, the crank wouldn't spin smooth or the engine would seize altogether from a valve stuck against a piston or something. I think we's all good.. seems so when hand spun.

You just left me short a quart or so of coolant! I would have it running right now otherwise lol.

I can't take it up and down the street anyways I have all the bikes and the garage so locked up I lost one of the keys to the five lock system. =P
I may have to saw the bikes out of the garage tomorrow morning.

Guess you can never be too safe!


after de-securing the rig tomorrow I'll slap the chain on and get the coolant and you'll be set.

[ninja250]

Originally Posted by Cazper

Wow that process and paperwork look strangely familiar!!! Glad to know that things are going smoothly on "good Kevin's" bike...lol. I also notice that much like our little ninjette's the exhaust seems to go out of spec more so than the intake... interesting note.

I'm sure his bike will run much better after this!!!

At Kevin's Mileage without adjustments, he's lucky he has any valves left in spec. lols. You kids is crazy. It was a pleasure working on his bike. Learning a lot from it.

I can totally see how these little engines work. I'm ready to tackle a few full size Honda Vtecs.
Maybe even rebuild my own busted CRX one day.

It's so amazing these engines can even actually operate the way they do with no bearings on the cams like that at 14,000rpm. Something goes wrong the cam or pieces of it could very easily come out through the valve cover.

We are relying on so many things to go right while we fly down the freeway on our bikes it's just plain scary.

The fact that humans can invent this momentarily perpetual mass of metal, natural and artificial materials to create power output in the form of horsies is amazing in itself. The whole chunk of hard metal runs off an explosive soft liquid refined from the earth itself too, no less.

It takes gases, liquids and solids to make this work right and they all have to be configured in exactly the right way.

[Cazper]

Sweet another valve job in the books!!! How long did this one actually take you? I would imagine a little longer just because it was a different kind of bike that you had to figure out what to take off etc.

Just curious

[ninja250]

Uh I had this one done in one day again.
accept I just broke a valve cover bolt just now and had to replace that for him lol. Luckily instead of having to wait a week for an order, the Ninjette has the same size valve cover bolts and I was able to take one off my bike and give it to him after extracting the busted bolt piece with a magnet.

Close call but still got him out of here today.
His bike feels much smoother and you can hear a major difference now.

That's when it's all worth while to me. When you guys are rolling away with a smile on your face.

Thanks for all your support and patience. I just hope I always get all your valve jobs correct so you don't sue me. I can't afford it! This is scary business for me in several ways.

[ninja250]

PS I totally kick azz on the Ninjette as a stunt bike ask Kevin! WHAT WHAT!
Representing the 250!

Juggling those stand up wheelies down the street lol

Did a lil micro clutch wheelie on Kevin's bike too trying to explode it and see if everything was OK.

[phr3ek]

he finished it in what seemed like 8-9 hours

couldve probably been done earlier if i had brought enough coolant

bike feels awesome, acceleration feels much smoother
and im sure it will improve my gas mileage too

thanks KC for the awesome job that you did
i highly recommend him for all your mechanical needs
we just need to get you hooked up with an impact gun

[phr3ek]

Originally Posted by ninja250

I just hope I always get all your valve jobs correct so you don't sue me. I can't afford it! This is scary business for me in several ways.

gotta start putting together a disclaimer form, or whatever it's called, to cover your ass

[ninja250]

True.
I'm pretty good about getting the timing right and all that stuff but unforseen stuff like that broken cover bolt is creepy. Sh*t can happen.

I'll have to start drawing up liability papers from now on.

Ah well thanks for reading my bike report guys. =)

[GeorgiaHooligan]

PS I totally kick azz on the Ninjette as a stunt bike ask Kevin! WHAT WHAT!
Representing the 250!

LOL