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Old 04-19-2011, 06:00 PM   #1
chris.mo.inc
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Help Troubleshoot my '03 636!

Hereís the deal guys:
Bike: 2003 Kawasaki Ninja ZX-6R

Iíve got a couple problems with my bike that I havenít been able to figure out. First up, the problem that is most pressing is that the bike wonít start, canít be jump started, canít be push started. When I try to turn it on, gauges light up just fine, fuel injectors turn on, but when I try to start it, all it does is click. Also, when I was in Austin two weekends ago doing a spirited ride, it just cut off on me randomly, wouldnít give me anymore power but the gauges were still on. As the bike coasted I just turned everything off and back on and it started right back up. WEIRD. Whatís not the problem: I know its not the battery, Autozone tested a few weeks ago and it was fine, I checked today and it was sitting at 12.24V. Battery connections are fine cuz the bike had been running fine right before it stopped turning on. Friend suggested the stator, but thatís been replaced quite recently. Other friend suggested the starter or starter relay, tested the starter relay today, its fine. Iím thinking the rectifier, but havenít had the chance to test it. SO, does this just sound like the rectifier for sure? Do I even need to test it? Or does it sound like its something else? Now that I think about itÖ I think the sound its making is quite similar to the sound my 94 accord made when it needed a new starter onceÖ Is it that???

Second problem: When the bike IS running, say Iím on the freeway, cruising about 70-80mph. something on the bike will kinda grab and make a sort of Ďbzzzzzí sound and slow the bike down around 3-4mph. Sometimes momentarily, sometimes for up to 10 seconds, then let go. Also, this happens completely at random, never on a regular basis, and not even at certain speeds really, I just gave the speeds above for example. Sometimes when it does this for a long time I give it more throttle and it lets go. One person said that it was the bike turning off and on at high speed because of a bad stator. Not sure how valid something like that is thoÖ More than one person had suggested that this was from the stator and thatís why I replaced it, but 3-4 weeks later this problem remains. What it could be: I kno for a fact the one of my front rotors is slightly warped, I can even hear it squeaking at low speeds, but I kinda feel like if that were to cause this type of problem it would be more of a constant thing, right? Iím really not sure what else could be causing this so any help or past experiences with something like this is welcomed.

All in all, I just wanna be back in the saddle ASAP like all of you guys so someone help!
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Old 04-19-2011, 06:02 PM   #2
Longdraw
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Well I am no mechanic & not familiar with Kawis.
Give Patrick at Motorcycles Unlimited a try if you can. He will take care of you.
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Old 04-19-2011, 06:24 PM   #3
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Second problem sounds like you might be losing power on one of the cylinders. Either fuel or spark. My harley would do that before I replaced the electronic ignition. On a V twin - the power loss is much more obvious on one cylinder (will barely run), but it did what you were describing only much more dramatic. Changed the exhaust note and lost power / speed. But guessing over the internet is just that - guessing.

+1 on calling Patrick at Motorcycles Unlimited.
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Old 04-19-2011, 06:59 PM   #4
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The starter is not what's killing it while riding. Is there a power commander?
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Old 04-19-2011, 07:10 PM   #5
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Try seafoam for the injectors and the rectifier
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Old 04-19-2011, 09:04 PM   #6
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Quote:
Originally Posted by bluewave18 View Post
The starter is not what's killing it while riding. Is there a power commander?
Yeah there is, I keep forgetting to re-map it. Its mapped to stock right now but I have a Yoshi... I'll do that as soon as I get it back running. You think that's causing an issue?

Quote:
Originally Posted by PYROBUG51 View Post
Try seafoam for the injectors and the rectifier
Okay... but, I'm still a newbie to working on the bike myself. SO, what's seafoam, what's it do, and where do I get it?
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Old 04-19-2011, 09:06 PM   #7
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disconnect the PC all together and see what happens
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Old 04-19-2011, 09:15 PM   #8
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Quote:
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disconnect the PC all together and see what happens
im with this guy. power commanders (I, II, III, V) are all garbage. at some point in the units life, it will fail.
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Old 04-19-2011, 09:16 PM   #9
chris.mo.inc
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Quote:
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disconnect the PC all together and see what happens
Do that now and see if it starts?
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Old 04-19-2011, 09:18 PM   #10
chris.mo.inc
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im with this guy. power commanders (I, II, III, V) are all garbage. at some point in the units life, it will fail.
Oh wow, hadn't heard that... I'll have to remember that for the next bike. So what tuner do you use if not a Power Commander? This PCIII was on the bike when I got it.
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Old 04-19-2011, 09:33 PM   #11
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Quote:
Originally Posted by chris.mo.inc View Post
Do that now and see if it starts?
idk if that will help the starting issue, but it might fix the other issue.
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Old 04-19-2011, 09:43 PM   #12
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Quote:
Originally Posted by chris.mo.inc View Post
Oh wow, hadn't heard that... I'll have to remember that for the next bike. So what tuner do you use if not a Power Commander? This PCIII was on the bike when I got it.
they are good for entry-level tuning, and downloadable "easy to install" maps, thats about it.
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Old 04-19-2011, 09:53 PM   #13
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They need their updated sometimes too. I have never had an issue with my Bazzaz.
I asked about the PC for reason. My bet is unplug it and not only will stop the BS but run better. I have tried to download so many different maps without a difference.
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Old 04-20-2011, 02:20 PM   #14
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Hey guys, I took loose the PCIII and the bike is starting up and running better than ever now. Thanks!

And hey, so is it shot and needs to be trashed or could someone else still possibly make use of it?
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Old 04-20-2011, 02:26 PM   #15
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Old 04-20-2011, 04:11 PM   #16
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You can probably update the firmware. Call PC and they will run you through it.
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Old 04-20-2011, 11:36 PM   #17
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Old 04-21-2011, 12:01 AM   #18
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good job guys and another biker saved by MH
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