2003 ZX6R - Dies/Stalls when RPM drops - ZX6R Forum
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post #1 of 11 Old 05-17-2013, 12:28 AM Thread Starter
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2003 ZX6R - Dies/Stalls when RPM drops

Hey guys/gals,

So I purchased my 03 ZX6R about 2-3 months ago. Buying the bike I knew it needed a valve adjustment as they were extremely loud. Plus the bike (at the time) had 20k miles and when I asked the owner about maintenance all I got was "I did oil changes every 3k".

So after saving enough cash I took the bike to a kawi dealer for a 24k mile service and asked they also adjust the valves (manual says this is at 15k service). I won't go into detail about the bad experience I had with the dealer, long story short the bike doesn't run correct now....

So after the service the bike dies when coming to a stop. This happens just after pulling the clutch in. Its off and on in first/second, pretty much guaranteed to happen in any other gear. Easiest way to make the issue happen is to pull the clutch while on the freeway, bike pretty much instantly dies. I don't do this normally, only after making a change and testing if my change fixed it. Reason being, it always happens in this scenario, doesn't always happen when coming to a red light or stop sign.

The dealer pretty much said it was my throttle bodies. They synch'd them then said the issue started to happen. According to them, they:

synchronized -> test road -> immediately checked synch -> TBs are out of synch.

They claim to have done this 4 times. Each time the bike came back with the TBs out of synch. They quoted me $1300 for a new set...

So i took my bike as it sat as it was my only choice (again, not gonna get into that, just want help fixing the bike). So far I have done the following:

1.) Adjusted clutch cable
2.) Adjusted both throttle cables
3.) Replaced Throttle Bodies with a working set
4.) Tested resistance on Sub throttle sensor, tested good
5.) Turned on ignition with airbox removed, sub throttle sensor opens and closes as it should
6.) Replaced ECU with known working ECU
7.) Adjusted idle speed to 1300-1500. Even set this to 2000 same issue
8.) Kick stand was a bit loose. The fail safe wasn't working all the time so when the kick stand was down and the bike put into gear the bike wouldn't shut off. After tightening all this down, it now operates as it should.

So after all this I'm kind of lost. Last thing I did was replace the ECU. I test road the bike to work and noticed it was running a bit hot, like 210+ Degrees. Started to think about this and I think I might be running lean. Here is why:

1.) Bike has Micron high mount
2.) Dealer installed a K&N filter, it was stock before
3.) Bike is running hot
4.) If I blip the throttle, idle sticks for 2-3 seconds then drops down

So I guess my biggest question is would a lean condition cause the issue I am having and are these considered symptoms of a lean condition? I can see this being a part of the problem, I just want some more opinions before I spend the cash for a PCIII. I'll end up getting a PCIII eventually anyway but i'd rather fix the problem at hand first.

Any and all help is greatly appreciated.
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post #2 of 11 Old 05-17-2013, 06:07 AM
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Have you changed your spark plugs? When I first bought my 03 the previous owner never changed them so I did. Big difference. So try that and check your fuel pump maybe.
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post #3 of 11 Old 05-17-2013, 06:57 AM
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More air flow in and less back pressure from aftermarket exhaust could mean the bike is running lean, causing the higher temps. I've never heard of a lean condition causing the bike to stall when the clutch is disengaged. Unless it's so lean that when the RPMs suddenly drop from the clutch disengage there's not enough fuel for spark, but that doesn't even make sense as I type it. Do you have an adjustable fuel controller? I have a buddy who put new pipes and K&N filter on his Victory 8ball and it ran like shit until he got his fuel controller dialed in right. Did you verify that your clutch is fully disengaging when pulled in? Could be just a normal stall if clutch isn't fully disengaging.

And I believe that concludes my rambling stream of conscienceness post.

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post #4 of 11 Old 05-17-2013, 03:11 PM Thread Starter
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Quote:
Originally Posted by MustangDroid View Post
Have you changed your spark plugs? When I first bought my 03 the previous owner never changed them so I did. Big difference. So try that and check your fuel pump maybe.
Spark plugs have been swapped out.

Quote:
Originally Posted by rhoadsr View Post
More air flow in and less back pressure from aftermarket exhaust could mean the bike is running lean, causing the higher temps. I've never heard of a lean condition causing the bike to stall when the clutch is disengaged. Unless it's so lean that when the RPMs suddenly drop from the clutch disengage there's not enough fuel for spark, but that doesn't even make sense as I type it. Do you have an adjustable fuel controller? I have a buddy who put new pipes and K&N filter on his Victory 8ball and it ran like shit until he got his fuel controller dialed in right. Did you verify that your clutch is fully disengaging when pulled in? Could be just a normal stall if clutch isn't fully disengaging.

And I believe that concludes my rambling stream of conscienceness post.
I have no way to compensate for fuel right now im probably going to get a PCIII from ebay tonight. Clutch has been verfied.

Thanks for the ideas so far guys!
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post #5 of 11 Old 05-17-2013, 05:43 PM
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Drums had absolute control at full lean!
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post #6 of 11 Old 05-17-2013, 06:01 PM
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1st off i would stay away from that dealership bc sound like they dont no sh*t about bikes and just takin your money for guess work. i would check the fuel pump and make sure its workin properly also put some seafom in the tank and ride the bike if the injectors is clog this stuff will help and i doubt your bike is runin lean from just pipe/filter bc these bikes come rich from the factory.
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post #7 of 11 Old 05-17-2013, 06:15 PM
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Easy. Been there. Fuel pump.

You're welcome.
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post #8 of 11 Old 05-17-2013, 06:33 PM
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Shutting down does sounds like Lobster most likely nailed it, fuel delivery, could be clogged in-tank filter also. The bike should not run lean because of air filter & freer flowing exhaust because it compensates with the ecu. Does it backfire on decel? That is sure sign of running lean. The lean condition could be unbalanced throttle bodies with one or 2 very rich & one or 2 very lean. I would also see about checking the valves again, too tight intake could cause starvation & too tight exhaust will not let enough hot gasses out.

If it is the fuel pump, you don't necessarily have to use oem, I recently put a fuel pump for a 90-97 Accord into a VN1500 Nomad & worked great. Got the pump off ebay for about $35 delivered & cheapest OEM I found was about $550 delivered.

EDIT:::: Just looked & the fuel pump off ebay was only 18.99 delivered
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Last edited by Rickthefix; 05-17-2013 at 07:40 PM. Reason: added info
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post #9 of 11 Old 05-17-2013, 06:58 PM
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Quote:
Originally Posted by zx racer View Post
1st off i would stay away from that dealership bc sound like they dont no sh*t about bikes and just takin your money for guess work. i would check the fuel pump and make sure its workin properly also put some seafom in the tank and ride the bike if the injectors is clog this stuff will help and i doubt your bike is runin lean from just pipe/filter bc these bikes come rich from the factory.
Quote:
Originally Posted by Lobster View Post
Easy. Been there. Fuel pump.

You're welcome.
Quote:
Originally Posted by Rickthefix View Post
Shutting down does sounds like Lobster most likely nailed it, fuel delivery, could be clogged in-tank filter also. The bike should not run lean because of air filter & freer flowing exhaust because it compensates with the ecu. Does it backfire on decel? That is sure sign of running lean. The lean condition could be unbalanced throttle bodies with one or 2 very rich & one or 2 very lean. I would also see about checking the valves again, too tight intake could cause starvation & too tight exhaust will not let enough hot gasses out.

If it is the fuel pump, you don't necessarily have to use oem, I recently put a fuel pump for a 90-97 Accord into a VN1500 Nomad & worked great. Got the pump off ebay for about $35 delivered & cheapest OEM I found was about $550 delivered.
Boom




Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^
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post #10 of 11 Old 05-17-2013, 08:54 PM
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Re: 2003 ZX6R - Dies/Stalls when RPM drops

Battery?
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post #11 of 11 Old 05-18-2013, 05:58 AM
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Quote:
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Battery?
Very doubtful it would be a battery issue as the alternator takes over while running. Also if a battery issue, it would have a very hard time spinning the motor over to get it started.
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