Unfixable Kawasaki ZX6R

[@DLM-ty3rt]

Thanks for taking us with you on these journeys Jim, love seeing the diagnostic process

[@cbuzz2371]

Some excellent specific knowledge there. Much more straightforward when you know what you doing

[@FourIntoOne]

40 year in mechanic here. My worst nightmare - having a bike that is a dog, had the (usually non oem) parts canon fired at it repeatedly by several different "mechanics" hack job on the loom (my favourite) - I dont touch em anymore lol, been bitten to many times. Anyway - subscribed!

[@motorcycle_workshop]

This takes me back to the days, when converting these bikes to race or track bikes, we would make them keyless ignition and have them turn on just with the kill switch. So the 100 ohm resistor was needed to trick the ECU into thinking everything was OK even though the ignition switch was completely removed.

[@rolandsmith2141]

I was thinking about when I race loomed my zxr400 back in the day.........yep I found out about this the hard way.

[@N269]

It's a voltage divider.... And, yeah, it might be trial and error (as the second half of the divider - in ECU - might be active)... could have used a 1k pot to trim the voltage???? Then place a fixed resistor?

[@MrOutOfTheVoid]

Great "top tipw" as always. Never knew the clutch trick for the fuel pump, nor the 5v from ignition, so learned something new today. Cheers

[@Tim9999999991]

Got to love the rattle can black paint over brake fluid reservoir. You know its going to be a basket case on the paint job alone :D

[@yorkiecol7973]

3mins in as soon as you said it had a new after market ignition switch I thought ah no resistor to trigger the anti theft element in the CDI. and of course that was the issue. all you have to do is solder in the resistor to the sensing line (grey) and it's done, BTW the correct one to use was the 100omhs one 6.6v is correct and the one Kawasaki fits in OEM switches.

[@markt5426]

Hi Jim, You can't beat experience and it clear shows. Well done mate. 👍👍

[@Pentode3000]

Clutch or side stand switches are also often candidates which can be checked easily.

[@truthinaudio5917]

Was thinking the same thing at the beginning of the video

[@woodywood8755]

Glad you took the trouble to use the Easy Start - would have been an anticlimax for viewers not to hear it run. With a couple of ZXR rebuilds on the go myself I found it an interesting vid to watch, thanks.

[@stevenhoward8792]

Love watching you at work on your KZbin channel, I'm really interested in motorcycle mechanical work and finding faults and sorting out problems, im a total novice and have very limited knowledge and skills but watching you at work is very rewarding and your methodology and skills are very valuable to me, I'm really interested in improving my skill levels and knowledge so i can service my honda vfr800 2018, I've purchased a full 120 piece tool set and paddock stand for the front so hopefully I can carry out my own annual servicing and general upkeep of my pride and joy, anyway Jim thanks for the fantastic content and keep up the good work on your brilliant channel. 👏

[@SuperbikeSurgeryTV]

Thanks for your kind words. I'm glad you find it interesting and are getting a bit of value from the content 😁👍

[@richardcraig4036]

After TFI Friday and Top Gear Chris Evans became an excellent motorbike mechanic!! Keep up the good work, really enjoy the vids

[@bikersquest]

That would've been a pain to diagnose without knowing about that grey cables job. One of the cases where exp and manual may give you a hint.

[@colinmaddocks9352]

Yes... I have several 1990 zxr 750 h models and that grey wire on the left of the bike is generally always the problem.

[@martinjgooda]

As always, super interesting Jim. You are amazingly experienced and knowledgeable. I love the way you are able to properly diagnose before fixing the problem. Always the best for permanently solving issues.

[@NickScrivener]

Hey Jim. After refurbing two Gpz900R's, 4xv, two zzr600's I wish i had seen some of your videos. Subscribed

[@HalfdeadRider]

I've owned my 2000 ZX9r for 2.5 years now, never knew you could prime the fuel pump in that way, I must try it! 😎👍

[@pedrosousa7493]

Have you done it already?

[@HalfdeadRider]

@@pedrosousa7493 Yes mate, I did reply but seem to have been blocked or deleted, me trying it is on my page.

[@iananderson1422]

Jim. Love your content. I had a 2010 GSX1250FA two weeks after buying it I got the FI light on and no start pulled the codes from the diagnostic connector and it turned out to be the ignition switch. Error if I remember right was ECU wrong crank voltage

[@lenpalmer3725]

Interesting video - the benefit of experience shining through

[@firestorm755]

Very informative vid. First thing I would do is pull that loom off and right back to stock! I never knew that about the ignition switch or fuel pump prime. Love how everything is sprayed black too😂👍

[@charlies418]

It reminds me of a starting problem that I had on a car. After testing all the usual components I deduced that it had to be the ignition switch. I took it apart and found that over the years of turning the key, the sliding contacts were all burnt and pitted beyond repair. A new ignition switch resolved it.

[@user-bw5ib8ds1e]

I once grew an onion THIS big.

[@elobiretv]

Crazy that the guy didn't just try plugging the new switch in instead of paying another person to diagnose it. Good video anyway, I learnt something from it.

[@moonshinepz]

I'm 66. Had Kawasakis of all ages for 20 odd years, including 90s 6Rs never knew about the fuel pump priming gag! Told my mate about this who is a bike mechanic all his life, he hadn't heard of it either. Top Tip!

[@davidhailstone1519]

Jim, as you know im sure this system was to stop hot wire thefts, great video.

[@victorgonza4528]

Yes brilliant got start at the end , very good video thank you .

[@tomevans4078]

Diagnosis done properly!

[@flexjay87]

Good top tips on teaching about this particular problem !

[@jeffreythomas4283]

Just started watching excellent content

[@geraldfitzgibbon7428]

Great to see u back. An good job on that bike

[@matthewharmer1656]

Great video, love the easy start at the end,classic!

[@FREE_PUREBLOOD333]

Nicely worked through. Good luck with this one. Always worse when every man and his dog have been messing about with stuff previously.

[@douglasbaxter3346]

Anyone with older zxr that trying to bypass starter solenoid or fuel pump relay or switch block you have to as a resistance to 5v on the gray wire think it was 500ohm resistor but could be wrong,love your work

[@tubemunkytoast7760]

Great video as always. I put about 70k on an ZX6R F3 back in the day when I was a bike courier, it was like Trigger’s broom (replaced engine, frame, bodywork, suspension, brakes etc), luckily I kept the loom and ignition switch original by the looks of it.

[@Positiveaddicted]

some hondas have a zener diode instead of a resistor, had me scratching my head for a while after replacing the ignition switch on a hornet 600

[@EndlessDelusion]

My Bandit's key was getting unreliable and sloppy so I bought a cheap Chinese key set off eBay. Because I've been bitten before with bad new parts I checked the pinout and It had the wrong switch pattern inside, so I ended up swapping the new lock wafers in to the old switch unit. But at £30 for fuel, seat and ignition locks, I can't really complain.

[@IN_ZANE_]

Nice job love geeking out on these kind of videos. Electronics is definitely an area where I get a little lost as soon as it gets technical, but you explained it really well. If someone puts in an original ignition switch at a later date, would that create too much resistance and end up with too low voltage on the grey wire and not run?

[@sandyroadking]

Jim , your troubleshooting ways are amazing and as always informative.

[@nbowling10trio]

This was an awesome first sportbike for me. I had other standard bikes before it, xs and cb models. My 88zx6 got me hooked on sportbikes😂. Brings back memories

[@JimBiddle.]

Brilliant couple of tips there! Hello Sammy, from The Internets.

[@smerd1]

Wow, that was just great to watch 😮

[@rolandofurioso5498]

I had this problem on my Kawasaki Zephyr 1100 20 years ago. Ignition switch broke right into the weekend when i wanted to tour with friends...so i thought i just skip the key and start with short-circuiting the two cables. Interestingly it even had good sparks, but wouldn´t start at all. After hours of searching for the fault for not starting dispite having a spark (i almost lighted the bike up in anger,lol) i dismantled the switch and found a little resistance inside it, without it in the circuit the ECU would give a wrong ignition timing, so you have a good spark, but at the wrong time

[@scottwheeler5665]

Great job Jim 😎👏👏

[@hairybastid2692]

Thanks

[@SuperbikeSurgeryTV]

I think thats the first "Super Thanks" I've ever had. Thank you so much 👍

[@hairybastid2692]

@@SuperbikeSurgeryTV so pleased to see you producing videos again. I've learned so much from your content, mostly about my own limitations, but that's probably for the best! Cheers Jim, keep them coming!

[@dozerblade]

love the thought process, as you go along.

[@mattjacomos2795]

Good on you for taking on this basket case. Most shops would take one look and say no... It takes a lifetime of experience to do what you do.

[@stonelemon03]

and money and patience .

[@volvogt21]

I went keyless remote fob on a DR 650 and had to fit a resistor also as the genuine switch was being removed

[@cnclown8859]

sound like some of the stuff iv see. I also hate swopping parts but love the fixing things.

[@owensmith1258]

" I am so professional " should be your next t-shirt.😂 I'd buy it. Jim you mentioned the engine breater hose as in how hard the engine was breathing. Could you elaborate on your observation, please? Thank you.

[@SuperbikeSurgeryTV]

A very quick answer would be ....you wouldn't expect to see anything coming out of the crankcase breather while cranking an engine from cold. Likely cause would be fuel contamination in the oil.

[@owensmith1258]

@@SuperbikeSurgeryTV Thank you for your reply. I appreciate it.

[@jeffreylindop5782]

great detective work.

[@timjkiely]

brilliant diagnostics. well done

[@steveneastland4128]

Had a GPZ500 with the ignition switch issue, it had been replaced with a GPX600 ignition switch, the difference in one wire was all it took to render the bike immobile, if I recall correctly a genuine Kawasaki replacement was only £80

[@ThomasMoore.1]

@22:27 😂 Owner might have considered it. Great diagnostics Jim. This is excellent content.

[@schofferbrothers3559]

That bike looks mint compared to some of the bikes I work on.

[@douglasbaxter3346]

Randomly clicked on your vid and I own a 91 zxr750 and done a bit of custom work to it and found online about the gray wire on the switch with the resistor and I’m like hmm I bet it’s the gray wire on your bike or similar issue.i run stock key set for a reason you can solder in a resistor and run any old switch as I had keyless start at one point

[@RichardScovell-xz5nb]

A masterclass...superb, thank you

[@nitramh24]

Wow! Amazing content! Somehow the YT algorithm has decided to hide your content from the masses😂 All of your videos remind me of my love/hate relationship with my old carbed motorbikes, except that you're way better than me at fixing the things that are wrong with them! Greetings from a new subscriber in Norway! Oh, and btw, the Kawasaki fuel pumps also engage with the kick stand down, 1st gear and hit the starter button.

[@SuperbikeSurgeryTV]

Thanks for the kind words 🙏

[@peterferguson7679]

I love how you explain thank you

[@basilwatson1]

yes I remember that was the "resistor "? in the ignition switch ? wheeze that some japanese bikes at this time used ? my memory fails me I only came across it once , never knew it was 5 v with current ,,,

[@vxady123]

It's a qwak thing soon as you said had ignition then it can only be the grey 6v dropper wire

[@carlhansen8668]

Great video again.. Why did you not load the power and ground going to the ecu? As that test you done with the unplugged ecu did not mean anything really?

[@SuperbikeSurgeryTV]

Valid point👍 I think I did say that out loud!

[@phensriwood8081]

Sounds like a new loom would be a good starting point, better still get a donor bike and make one from two.

[@paulwatts905]

Wow, genius. Thanks for sharing.

[@derekwilson1771]

Great video Jim , really interesting , I own a Zxr 750 J (1991) and I had to change the ignition . The bike runs fine once it’s started , the problem is the fuel pump is not priming or doing anything and if stood for a week she takes forever to start . Would the possible omission of the resistor stop the fuel pump From priming . The pump works fine of the bike when connected to a battery , so I suspect faulty relay or having seen the info on the video , it may be the grey wire . Even the top tip of the clutch doesn’t do anything , no relay click or pump priming . Otherwise she’s great . Any advice would be gratefully received - many thanks and keep up the good work - love the channel , I learn every time ! Cheers Del

[@SuperbikeSurgeryTV]

Hi Del, thanks for the comment 👍The most likely cause is the relay, as you said. It's not a very complicated setup, so the fault should be easy enough to track down. If you need a full colour wiring diagram, head over to my Discord: discord.com/invite/9YX7M7EX You won't have access to the entire thing unless you become a Patreon, but send me a PM, and I'll send you the diagram. The user name is @jim (I'm the admin, so the name will show in green)

[@derekwilson1771]

@@SuperbikeSurgeryTV yo brother you’re a ferkin legend , I’ll do some testing and see how we get on , and a big thanks 🙏 👍👊🍺

[@-DC-]

Think your pants would probably out value this Machine Jim 🤣

[@brian623]

So clever top man

[@rc2634]

I just discover your channel, you are a legend. I just wonder how you discover that information about the resistor.🙂 I mean, I like to work on my bikes and I always use the workshop manual, I believe such information is not stated there or in the electrical diagram. I just wonder where to find more info. Anyway, I subscribed, excellent stuff

[@SuperbikeSurgeryTV]

Thanks for the comment, Information like that is hard earned! Although this little gem I got from a Kawasaki factory training course back in the day.

[@pavz]

Just discovered this channel. Subscribed :) Anyone knows what is the charger/power supply Jim is using in this video?

[@MrB1967]

You are a wizard 😎

[@leondavibe]

yea many don't seem to realise any carb bike that stands with undrained fuel turns into a non running bike with enough time, having a v4 nc30 (know the profile pic is a bit of a lie - my nc30 looks like nc35 though) i just make a point of riding it once a month at minimum cause getting at the carbs is always a fuss luckily here in South Africa we don't have to deal with any salt/snow on the roads etc

[@googlelimp9834]

hi you just hope the carbs don't piss you out of fuel what problem would that be?? i have that at the moment but does start ish

[@blandit74]

The little dude that you use to pull the wires out.Do you have a link that you can provide m Also where would I find replacement tips for those wires for exclusively japanese bikes

[@e2linuxos]

All good until the next guy fits the proper ignition switch. ;-) Wonder if it got back on the road? Subscribed as you are very methodical and skilled.

[@user-ot7fc8jo8x]

Awesome top tip👍👏👌

[@bizzie1956]

Think I will go and rid.e one of these because of your review of this machine ❤👍🏻

[@dougsmith7580]

“Well blow me.” I blew coffee all over the table and about fell off my chair.

[@johnchettleburgh6055]

'GTFOH' won me over!

[@joebloggs1583]

1 careful lady owner only 42 thousand miles 😎👍

[@Francois_Dupont]

it was my wife's.

[@Eastsussexbiker]

Thing is @16:34 your skill pays the mortgage and he came to you after the other mongs couldn’t sort it so it’s you that’s should charge as pay cheap pay twice.

[@Kjutte1]

impressive

[@pauladdison8961]

If you dont mind, what battery charger / maintainer are you using, that works on your phone ? thanks

[@SuperbikeSurgeryTV]

www.victronenergy.com/chargers/blue-smart-ip22-charger

[@literal_lee]

So that's what that 3rd wire on the clutch switch is for, right ? 🤔😂 I always wondered. The grey wire is a nasty one if you don't know about the resistor. That solves another mystery indeed. Cheers.

[@numptyadventures9207]

Float bow breather, would that explain fuel coming out also ?

[@teltwosheds2972]

Blegh child!😂 Great tips👍 30:20

[@yourundoing12]

you legend :D

[@andrewnewton5893]

I had a 1996 f3 was good bike once I rebuilt all fuel system lol

[@gerardmcconnon9155]

That was enjoyable

[@Si-vq5wg]

There are some jobs where you should simply be holding up the crucifix.The cheapest bikes with the complicated problems.Customer always states they want it fixed and running perfectly but they don't want to spend any money.Always the jobs that need time put into them.If its not an easy fix best to walk away from it as you can never recover all the time/hours you spend on them.

[@rolandsmith2141]

Knowing your bikes worth as much (or was it less than) your underpants Jim.😂

[@kevinchamberlain7928]

Nightmare! Going in after nincompoops = trouble!

[@Vincegould]

Could this be a problem on a 1999 r6? The ignition voltage issue.

[@SuperbikeSurgeryTV]

No, Yamaha don't use this system.

[@Vincegould]

I have the same problem on an r6.

[@geoepi321975]

Hi can someone find a schematic diagram of the OEM ECU, thanks

[@bikeserv]

Things like this makes me wonder about the work I chose sometimes

[@TheDervMan]

Mint

[@ironclay3939]

Hi there, new Subscriber had to stop an 8 month old video to make a suggestion - Customer doesn't want to spend money, he's already taken out 6 mortgages so we can assume that he's a Wee bit Reluctant to spend another Girlfriend on it so THE WIRING REMEDY: ps. How much is one of those cans of expanding foam ??? in the UK ... OK so here it's about NZ$40 and there's a Serious amount of foam in these things you can just let loose ... This is what I'd do if it was my daughters bike [or in your case your sons bike] Id get her/him to use something to ensure all the wiring was " not touching the frame " - and where ever it wasn't solid it needs to be rebound like a real lumen ... I'd get it working perfectly [with all the wired looking just like they are but not touching] and Bro I'd Let Lose with Expanding Foam, put it into all the corners that the bugs or water can get into and just act like the can will never run out ... Right? I believe expanding foam comes in 2 colours ... you may want to check with the Final Destination 5 Bike Customer ... 5 years down the bike track a new owner google searches "Foam Covered Kawasaki Wiring diagram" ...

[@cozydram1]

Neat

[@northernninjarunner5506]

Why not put the proper ignition on it and stop adding to the wiring bodges on the bike already?

[@Cochise6-6-6]

He's helping a customer out and doing the bare minimum to fix the no spark issue, as stated in the video

[@andyjdaviestjk]

You want to help them realise you have just opened the biggest can of worms ever 😞

[@steveclark..]

It's a real shame that some people let a vehicle get to this state, neglect and letting clowns work on them basically.

[@matthewjones5450]

Two rolls of electric tape and a five and a half resistor soldered in the grey wire fixed with no parts except tape and a six pound resister why the drama

[@tonywylde8211]

Fucking genius!