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Discussion Starter #1 (Edited)
2013 636 running rough mid rpm bogging issues

Hi guys,

Im having some mechanical issues with my 2013 zx6r 636 and I'm really stumped on what it could be hence why I am asking for some help or some opinions from you guys

My bike currently has 20 000km/12 500miles and it has developed a bog at mid range rpm 6-8k but only when I snap the throttle. It does not always happen when I snap the throttle but its becoming more frequent which is getting me worried about possible underlying issues with my bike. If I gradually roll on the throttle the bike will pull hard across the rpm range as it should but when I punch it the bike will sometimes bog down around 6-8k with a noticeable power decrease and if you hold the throttle and try to ride it out, the bike will slowly climb in rpm with a huge lack of power and begin to top out around 11-12k and run really rough until you let off of the throttle. Again it doesn't always happen but its starting to happen more often.

When the bike doesn't bog, when I snap the throttle it will pull hard throughout the rpm range as it should. Some times the bike will only bog from 6-8k and then regain power and take off and sometimes it wont regain power and continue to bog to 12k rpm as mentioned previously.

Can anyone help me diagnose this problem I am having. I've tried to cover as much as possible and still can't solve it. Any help will be greatly greatly appreciated! I really hope its nothing major, Im getting tired of taking my bike apart every day trying to solve this!:eek:mg:


Some more info to answer most questions.


  • 100% oem mechanically - got stock exhaust with prechamber+servo

  • No engine light or light on cluster

  • motul 7100 oil, at 50% life

  • New oem air filter

  • Cleaned fuel pump strainer, fuel pump primes better

  • Fresh gas 91 octane with seafoam treatment

  • New iridium spark plugs 2 months ago

  • Checked coil stick resistance, both primary and secondary windings were within oem specs

  • Checked injectors resistance, all were within oem specs

  • Pulled battery to reset ecu

  • Inspected function of servo under the exhaust cover
  • Tested fuel pump pressure - 43psi when running and some light revs
  • Fuel pump flow rate - 100mL in 3 seconds, exceeds oem specs
  • Throttle sensor+secondary butterfly valves resistance checked
 

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What's your traction control setting?
 

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Discussion Starter #5
could be lack of fuel pressure

heres a guide, had a similar prob on my 10

How to Test the Fuel Pump in the Kawasaki Ninja ZX-6R | eHow UK
I took my tank off and tried cleaning the strainer again with some compressed air. I did a flow test and in the 3 second prime 100mL of fuel came out. That is well above the "50mL or more for 3 seconds" stated in the service manual. I also did the pressure and it stays at a constant ~43psi when the pump primes, also when the bike is running with a few revs.

What's your traction control setting?
Was going to ask the same thing. Have you looked at the gauge cluster to see if the traction control bars come up when it's happening?
My TC is set to 1 but it's not the TC going off, its a different feeling. You can feel the motor bog down and even shake a bit.

I am hoping this tank of gas with the seafoam treatment helps. I'm thinking the injectors could be dirty, otherwise I am really out of ideas. It also doesnt help that the temperatures are dropping so much so quick! It's almost time to tuck the bike away.
 

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Discussion Starter #7
Check your tank's breather hose for a slight pinch.

jimundascores
I double checked the breather hose and also verified that it wasn't pinched or plugged any where when reinstalling the tank.

I recently had 2 tanks of 91 gas with seafoam treatment mixed in the gas at a mixture of 1oz per 1gal of gasoline. I did notice the bike running a bit smoother and it really did help out with the hesitation issue BUT the problem is still there. The bike still bogs when I crack the throttle but it's not happening as often as before but enough to still notice it.

I'll be around 6-7k rpm in 3rd and ill snap the throttle and allow the bike to accelerate and the bike starts to pull but it wont accelerate as its suppose to, you can feel it struggle from 7-10k rpm and at 10k you feel sort of a dip in power and it kicks back in and continues to struggle but it wont make it past 12k rpm. This is when the bike runs the roughest, sometimes it will just bog from 7-10k, but you can feel it regain power and boost back to normal power from 10k and beyond. Feels like when the throttle is snapped open the bike suffocates with too much air or something, and has a hard time breathing normal again.

I've checked the resistance of my throttle sensor and made sure nothing weird was happening with the throttle at different positions. Nothing funky was happening when I was snapping the throttle. The throttle sensor readings were consistent and sensor seems to be doing its job.

I also checked the sensor for my secondary butterfly valves and made sure the readings were consistaent and not doing anything funky when moving the valves.

I also took apart my clean air system, cleaned the caps (where people would normally install block off plates) and also cleaned the reed sensor. I cleaned the butterfly valves and throttle body. Cleaned the airbox and the ram air vent.

Tried to cover as much as I could and the problem is still there. My efforts arent wasted as it has improved in terms of happening not as frequent and the hesitation is to a lesser degree than before.

I am out of idea's right now for what it could be, I am going nuts not being able to solve this problem. Knowing my bike isnt running at 100% really bugs me. I'm really considering of selling the bike at this point and buying something else with lower mileage. I know SOMETHING isn't running up to par which is why this issue is present.

Any other idea's? fuel injectors? maybe my bike needs to be remapped? New fuel pump?

I really love this bike and its killing me knowing its not running like it should especially being only 2 years old.
 

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Pull the plugs and inspect them, I am going to bet you are finding they are fouled.

Iridium plugs offer increased longevity from the plug but in performance equipment I have never seen anything but trouble from them. I would run a standard plug (CR9E) in it and see if the problem persists.
 

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Discussion Starter #9
Got a new set of spark plugs(ngk cr9e installe and he problem is still present.

The iridiums were worn consistently and didn't show signs of fouling when I compared them to pics online.

Was really hoping the iridium plugs were the culprit! I'm getting tired wondering what could be wrong!!

I'm thinking it could be the injectors now that we ruled the plugs out...
 

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Discussion Starter #11
Wild guess but could valve clearance be an issue
I think valve clearance is up next for me, that wont be until the winter months though. Been a bit busy to ride lately but I'm still trying to figure this out lol.

Anyways I have a few quick clips of the bike kind of hesitating. Each pull I have the throttle at WOT and the throttle is snapped on and not rolled on.

https://youtu.be/b4xR_2dI9Z0



The first pull in the video is the worse one because it begins hesitating right upon acceleration and it holds it throughout the rpm range. At the moment it usually hesitates a bit and then the bike picks up and takes off.

any other suggestions?
 

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Check those plugs.

Have you changed your gearing any? If so, I may have dome insight on the issue
 

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I know it's been some years since this post,but I have a 2016 zx 636 that is having this exact issue.Has there been a remedy to the issue,any adive would be great as it is driving me nuts.
 

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I am having a very similar issue with my 2009 ZX6R track bike...

Bought the bike in March 2019 from KY with 2300 miles on it.

Had about a half tank of old fuel in it from summer/fall 2018. Ran awesome on the initial test ride
Brought bike home to MI changed all the fluids new plugs, fresh fuel etc. Also had some dodgy wiring with the PC5 and grounds so i go through ENTIRE bike and clean all that up.

Ran first track day, and in about the second session it started cutting out at 10-11k rpms
Kept trying to go out and have fun in the corners but i ended up lowsiding and ending my day.

Bring bike home.
changed fuel filter
new plugs again (just to be sure)
inspected fuel pressure at prime, running, and revving. (all good)
Cleaned fuel tank.
checked ohms on injectors (all good)
checked voltage at injector leads (all good)
checked voltage at coils (all good)
Checked ohms at Coil packs (all good)
checked throttle body (all good)

Put the bike back together, runs awesome.

Do another track weekend, bike runs all the way through the revs with no issues at all.

The very next weekend I ran a CCS race at Balckhawk Farms. No issues whatsoever.

This weekend 8/10-8/11 I ran another track weekend at Gingerman raceway.
1st session, bike runs great goes all the way to redline with no issues at all.
2nd session, bike is bogging around 14.8-15k (low fuel light comes on about 1 lap in)
3rd session, full tank of fuel, still cutting out. Now starting at 14k rpm (will still make it to 15.5K but it struggles to get there)
4th session, bike is now cutting out starting at 13k

Lunch: I drain the fuel and put in a brand new fuel pump and filter.

5th session, bike runs amazing for 3-4 laps all the way to red line, then starts bogging again at 14.5 then gets worse all the way to 13k again...
6th session removed PV5 and all wiring bike now starts bogging/ losing power at 12krpms. at this point I can no longer run Advanced pace and I kill the bike for the day.

A close friend loans me his 07 zx6r for the rest of the weekend and still had a killer time.

I am now lost.. I have a race coming up this weekend. 8/17-8/18 at BlackHawk Farms and i have no idea what to do to get this bike ready.

any help!?

-Billy
 

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Spark or fuel, one or the other. I don't see where you changed the coil packs. It doesn't appear the bog/miss is consistent. I would look at replacing the coil packs.
 

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I am having a very similar issue with my 2009 ZX6R track bike...

Bought the bike in March 2019 from KY with 2300 miles on it.

Had about a half tank of old fuel in it from summer/fall 2018. Ran awesome on the initial test ride
Brought bike home to MI changed all the fluids new plugs, fresh fuel etc. Also had some dodgy wiring with the PC5 and grounds so i go through ENTIRE bike and clean all that up.

Ran first track day, and in about the second session it started cutting out at 10-11k rpms
Kept trying to go out and have fun in the corners but i ended up lowsiding and ending my day.

Bring bike home.
changed fuel filter
new plugs again (just to be sure)
inspected fuel pressure at prime, running, and revving. (all good)
Cleaned fuel tank.
checked ohms on injectors (all good)
checked voltage at injector leads (all good)
checked voltage at coils (all good)
Checked ohms at Coil packs (all good)
checked throttle body (all good)

Put the bike back together, runs awesome.

Do another track weekend, bike runs all the way through the revs with no issues at all.

The very next weekend I ran a CCS race at Balckhawk Farms. No issues whatsoever.

This weekend 8/10-8/11 I ran another track weekend at Gingerman raceway.
1st session, bike runs great goes all the way to redline with no issues at all.
2nd session, bike is bogging around 14.8-15k (low fuel light comes on about 1 lap in)
3rd session, full tank of fuel, still cutting out. Now starting at 14k rpm (will still make it to 15.5K but it struggles to get there)
4th session, bike is now cutting out starting at 13k

Lunch: I drain the fuel and put in a brand new fuel pump and filter.

5th session, bike runs amazing for 3-4 laps all the way to red line, then starts bogging again at 14.5 then gets worse all the way to 13k again...
6th session removed PV5 and all wiring bike now starts bogging/ losing power at 12krpms. at this point I can no longer run Advanced pace and I kill the bike for the day.

A close friend loans me his 07 zx6r for the rest of the weekend and still had a killer time.

I am now lost.. I have a race coming up this weekend. 8/17-8/18 at BlackHawk Farms and i have no idea what to do to get this bike ready.

any help!?

-Billy
Did you find a permanent solution? I’m having the same issue on my 09 zx6r.
 

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Billy's problem turned out to be a bent fuel pump assembly nozzle.. if it is the same author of the post as another forum I read his story.
Swapped the tank out and bike ran perfectly..
 

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I took my tank off and tried cleaning the strainer again with some compressed air. I did a flow test and in the 3 second prime 100mL of fuel came out. That is well above the "50mL or more for 3 seconds" stated in the service manual. I also did the pressure and it stays at a constant ~43psi when the pump primes, also when the bike is running with a few revs.





My TC is set to 1 but it's not the TC going off, its a different feeling. You can feel the motor bog down and even shake a bit.

I am hoping this tank of gas with the seafoam treatment helps. I'm thinking the injectors could be dirty, otherwise I am really out of ideas. It also doesnt help that the temperatures are dropping so much so quick! It's almost time to tuck the bike away.
I have same problem when i put the tc to off the bike work so good but if i put it on the 1-2-3 the bike bobing any help for that?
 

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Not sure what you mean ? " when i put the tc to off the bike"

I figured out a few more things with this issue (but that's on my 08)
 
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