ZX-6R Routine Maintenance

Doing minor maintenance on your own bike has several advantages

  • It’s very satisfying, and a big ego boost. Every time I tackle a new maintenance chore, I feel proud (after fixing any screw-ups), and find myself bragging about it to friends who have no idea what I’m talking about.
  • You develop a much better understanding of what’s going on in your bike, which builds confidence and removes some of the mystery.
  • After some investment in tools, it can save you money. Although you pay more for parts than dealers’ internal costs, most maintenance charges are labour and, if you consider doing it yourself a hobby, your labour is free.

I am not a mechanic, but started with a basic tool collection, bought the service manual for my bike, and can follow instructions. I’ve been tackling various maintenance chores of gradually increasing complexity. If I can do these things, you certainly can.

The following photo-journals are my way of getting myself out of trouble if I take something apart and can’t remember what it is supposed to look like reassembled. If they help you decide to tackle a maintenance task, I’m pleased. Use these journals and photos as inspiration, not as instructions — follow the instructions in your maintenance manual.

I’m sure that, in almost every case, there are more efficient ways to do these things. I tend to take a step-by-step approach with no shortcuts, as I’m doing this for fun not for profit.

Basic Tools

Some of the tasks below require specialized tools. But there are certain tools common to almost all maintenance tasks, including a few that, while “optional”, I’ve found to be indispensable and highly recommend. Note: some of these tools are included in the tool kit that came with your bike — you should inspect those and see if you’re satisfied with them (I wasn’t).  Here’s the basic list.

Neighbours in non-metric countries: Japanese bikes use metric fastener sizes. Don’t try to make your imperial tools do the job — you’ll round off bolt heads and cause yourself grief. Get metric tools.

Maintenance Suggestions

Here are some feasible home maintenance chores. These are roughly in order of increasing difficulty, but all are things I have done successfully — so you can too.

These pages are permanently under construction and tend to get attention mainly outside the riding season. Links will be filled in as the appropriate page is ready.

Plan in advance and save time

Take a few minutes to plan your tasks before starting. There are a number of maintenance tasks that it makes sense to do at the same time, based on where you have to go in the bike to do the work. For example, if you have to take off the gas tank and carburetors to check your valve clearances, that would be a good time to service your spark plugs too. That would make much more sense than having to go through all the effort of taking off the tank and carburetors two times because you didn’t plan to do those chores together.

Minimal disassembly required

Trivial to do, requires no tools or disassembly, starts your basic familiarity with adjusting your engine.
Simple to do with only basic tools, saves you money, and improves the health of your bike. A great starter project.
Lubricating your clutch cable is easy with a special tool, and will prolong its life.
Change your antifreeze. Or, replace it with water for a track day, then back again after.

Things requiring more disassembly

The following chores take somewhat longer because they require access to the engine, which means at least taking off the gas tank, and possibly other disassembly. Don’t let this intimidate you, but do allow lots of time and don’t attempt these when you’re in a hurry.

Easy to do and, in dusty or dirty environments, improves performance noticeably.
Lubricating your fuel cables is easy with a special tool, and will prolong their life.
Remove and inspect plugs. Clean and gap, or replace, them.
This easy-to-do maintenance task improves performance but requires a couple of specialized tools.
The most complex thing I’ve tried yet. It’s remarkably simple to do, but very time consuming because the parts you need to access are deep inside, much disassembly required.


  1. Hey my fuel pump when on the bike. Had to get a new one with filter. Any tips on how to change it

  2. Hey Richard hope everything is going good. I emailed you a while back about how helpful your guide was when i first purchased my 2002 zx6j. Well i just wanted to give you the update that i have now completed every task on this list! Before i bought my bike i had never touched one so your guide has basically taught me everything i know about motorcycles. I dont know how i can thank you but please keep it up, i know people will be using this guide for many years to come.

  3. this site helpt me very much last year,
    tomorrow i am going to check my valves again.
    keep up the good work

  4. Please please never take this down it really helps everyone and saves people money.
    Thank You!!

  5. Good guides, cleaned the air filter and checked plugs tonight, was going to wait for a Haynes manual but gave it a go with your guides anyway. Clear diagrams and easy to follow instructions. Thanks.

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