Unfixable Kawasaki ZX6R

[@DLM-ty3rt]

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

[@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

[@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?

[@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!

[@davefarmery8180]

Plz don't ever give up on the videos Jim , you are an incredible bike mechanic and with all that knowledge you have stored in that brain of yours it would be a shame not to help others , Your videos are an inspiration that help people get off their arse and have a go themselves 👍

[@garywilde6171]

Haven't had a bike for 40 years, but really enjoy your process of fault finding, and I admire your knowledge and expertise. Your reaction to the air compressor going off is hilarious, and reminds me of myself. I'm tempted to get back into biking to scratch the itch.

[@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!

[@juancarlossanchez759]

I enjoy your interaction with your assistant. What you do with your kids when they're little pays dividends fir tge rest of both your lives. Looking forwards to him being more part of your videos, he sounds like a good lad.

[@markt5426]

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

[@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 😁👍

[@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.

[@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.

[@Amduscias13]

100 OHMS 1/2...NOT 1/4 what most people say!

[@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.

[@Amduscias13]

The manual gives you NADA I'm afraid...This is all down to experience I'm afraid!

[@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

[@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

[@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.

[@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

[@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?

[@cbuzz2371]

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

[@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!

[@juancarlossanchez759]

I recently found your channel, I guess I should thank the YT algorythm. I'm not a mechanic but have a very curious and analytic mind, also a previous motorcycle owner for nany years. Yoyr videos are very fun and informative. Another channel I enjoy is The Bearded Mechanic, he is very funny and passionate about motorcycle repair. As I follow your videos, it hassurprised me how much I can follow your descriptions of the problems your finding and how to fix them. I guess I know more about motorcycles tgan I thought but also makes me respect proper mechanics because knowledgeable one can make repairs look easy. Keep up the good work. 👍

[@lenpalmer3725]

Interesting video - the benefit of experience shining through

[@tomevans4078]

Diagnosis done properly!

[@richardcraig4036]

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

[@ianhoyle8459]

Nice soldering and fantastic problem solving skills 😊

[@sandyroadking]

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

[@dozerblade]

love the thought process, as you go along.

[@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.

[@victorgonza4528]

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

[@matthewharmer1656]

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

[@guycarpenter5719]

truly amazing skill...amazing mechanic

[@davidhailstone1519]

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

[@flexjay87]

Good top tips on teaching about this particular problem !

[@volvogt21]

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

[@markleader2622]

Very impressed Jim. Top job 👍

[@jbsworkshop]

I had a Zx9r with a no spark issue & it ended up being the switched power feed to cdi box broken from the fuse box,took a bit of fault finding but got there in the end. Enjoy you video’s 👍

[@ThomasMoore.1]

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

[@geraldfitzgibbon7428]

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

[@jeffreylindop5782]

great detective work.

[@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.

[@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😂👍

[@JimBiddle.]

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

[@Simplyrecovery]

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

[@joshdeb]

Love watching your videos. Your knowledge and fault finding is cool .

[@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

[@vxady123]

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

[@scottwheeler5665]

Great job Jim 😎👏👏

[@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.

[@ArthurTanner-d7s]

I once grew an onion THIS big.

[@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 ,,,

[@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.

[@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!

[@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.

[@numptyadventures9207]

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

[@timjkiely]

brilliant diagnostics. well done

[@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.

[@chrisleighton5102]

U don't need to use the clutch to prime the pump, just side stand down bike in first gear push start button, and the pump will prime or that's in my experience after having 2 zx9r and my mate has a zx6r and a zx9r and it's the same on all of them

[@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

[@cnclown8859]

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

[@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 🙏 👍👊🍺

[@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 .

[@NickScrivener]

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

[@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

[@pavz]

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

[@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

[@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

[@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

[@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

[@jeffreythomas4283]

Just started watching excellent content

[@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.

[@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 🙏

[@smerd1]

Wow, that was just great to watch 😮

[@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.

[@paulwatts905]

Wow, genius. Thanks for sharing.

[@peterferguson7679]

I love how you explain thank you

[@RichardScovell-xz5nb]

A masterclass...superb, thank you

[@phensriwood8081]

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

[@-DC-]

Think your pants would probably out value this Machine Jim 🤣

[@geoepi321975]

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

[@Vincegould]

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

[@SuperbikeSurgeryTV]

No, Yamaha don't use this system.

[@IanLawrie-l9q]

Awesome top tip👍👏👌

[@MrB1967]

You are a wizard 😎

[@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.

[@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.

[@schofferbrothers3559]

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

[@Vincegould]

I have the same problem on an r6.

[@Kjutte1]

impressive

[@brian623]

So clever top man

[@newvideosdaily9025]

I need help please!! I have a 1992 Kawasaki zx-600d and my bike won't even crank over :( can someone please help me

[@joebloggs1583]

1 careful lady owner only 42 thousand miles 😎👍

[@Francois_Dupont]

it was my wife's.

[@bizzie1956]

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

[@steveclark..]

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

[@riderzinc]

I just change the loom if its a mess like that

[@rolandsmith2141]

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

[@juancarlossanchez759]

Ever thought about working on electric motorcycles? You seem to know a lot about electronics and enough passion about motorcycles to create engaging content similar to your internal combustion videos

[@johnchettleburgh6055]

'GTFOH' won me over!

[@andrewnewton5893]

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

[@davidwilson8010]

Currant to the coils but no sparks from the plugs..

[@bikeserv]

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