Took the bike apart today, a LOT of questions *PIC HEAVY* - ZX6R Forum
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post #1 of 9 Old 03-02-2017, 03:36 PM Thread Starter
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Took the bike apart today, a LOT of questions *PIC HEAVY*

Hey guys, recently bought an 05 ZX636 off Craigslist. They said it was going to be built to stunt then decided not to. While removing the PO's crappy "body glow LED" wiring job, I noticed a bit more about the bike and have some questions. I took a lot of pictures, but some are blurry because my camera lens is cracked:

She's quite naked:


I liked the lights but this guy sucked at wiring:


Is this the ECU or what is this? If it is the ECU, I read about people relocating it. Any info?:


I was told the black plug and that silver part (black circle) has something to do with the aftermarket exhaust and allowing it to pass inspection or something? I also found an orange wire with a connection on it but no wire going through on the other side, no clue what that is (circled in blue). Update: Drove bike back to school today, FI light was on. Did this thing get reset? I read that FI light means exhaust ports aren't opening or something:


That's a lot of wires for the integrated taillight/blinkers:



My chain broke on the road and my buddy's cousin was able to come two hours later with a trailer. Had to lay the bike down and I guess some gas leaked. Looks like I'm gonna have to repaint her:


She definitely needs a new coat of paint this season!:


There's a bit of play and I feel like I need to lift my foot pretty high (compared to my Suzuki) to shift. Is there a way to tighten this up a bit?:


My speedometer shows random numbers after about 25mph, found this clip with some sort of glue on it as well as it was tied in with string. Where could I get a new connection for this?:


Just curious what those wires are, appear to be blue and yellow:


When removing the front fairing around the lights, I unplugged some of these connections. However, found the circled clips unplugged already. What are they?:


Aftermarket rear brake pedal was apparently installed, leaving this unsecured and not connected. Macgyver'd something with some metal wire to connect this to the new pedal:


Freakin radiator bolt was missing so it's just hanging there:


Rotors appear good and the brakes felt alright, but noticed that the back plates were rusted so these will be changed soon too:



Chain broke so I inspected the sprocket, seems to just be a little dirty but overall in good shape:


This tube was loose and was connected to the coolant tank under the gas tank. Is it a breather/vent tube? Should it be connected somewhere?:


Also found this little guy hanging out, what is it?:


Link to imgur album in case pictures don't show up
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post #2 of 9 Old 03-02-2017, 03:54 PM
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First, my rudest comment: I don't think anyone ever 'has to lay it down'. Sure, sometimes you crash. Maybe you did in this case. But if you crash, it should have been unavoidable. You should never intentionally lay it down. Staying on the brakes is always a better option. (Or did you mean after you stopped there was nowhere to put it on the kickstand so you layed it in the ditch? Sorry if I misread that).

That said:

The little white bottle is oil overflow catch from a breather.
The hose that goes nowhere is a breather. It doesn't attach to anything.

The white/black thing is an exhaust servo. It isn't used if you have aftermarket exhaust. If it's left plugged in, it'll click clack. If you unplug it without jumpering it, it'll throw an FI light.

How did the chain break? Overtight? Old? I realize I made the same mistake when I was new, but you really should inspect something like that and be confident its correct before it causes you to crash.

The Macguyver thing is your rear brake light switch. It should have a wire going to the rear brake lever so it 'clicks' when you apply the pedal.

The bike has been crashed before. The wiring to the speedo has been glued in because the speedometer was cracked/busted and the clip wasn't there, so they just stuck it in place and glued it. A new speedometer is like $90. Clean off the crud and plug your wiring into your new one.

The shifter can be adjusted for angle, but if there's looseness in it, I think that's internal.
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post #3 of 9 Old 03-02-2017, 04:58 PM Thread Starter
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Quote:
Originally Posted by commiehunter View Post
First, my rudest comment: I don't think anyone ever 'has to lay it down'. Sure, sometimes you crash. Maybe you did in this case. But if you crash, it should have been unavoidable. You should never intentionally lay it down. Staying on the brakes is always a better option. (Or did you mean after you stopped there was nowhere to put it on the kickstand so you layed it in the ditch? Sorry if I misread that).

That said:

The little white bottle is oil overflow catch from a breather.
The hose that goes nowhere is a breather. It doesn't attach to anything.

The white/black thing is an exhaust servo. It isn't used if you have aftermarket exhaust. If it's left plugged in, it'll click clack. If you unplug it without jumpering it, it'll throw an FI light.

How did the chain break? Overtight? Old? I realize I made the same mistake when I was new, but you really should inspect something like that and be confident its correct before it causes you to crash.

The Macguyver thing is your rear brake light switch. It should have a wire going to the rear brake lever so it 'clicks' when you apply the pedal.

The bike has been crashed before. The wiring to the speedo has been glued in because the speedometer was cracked/busted and the clip wasn't there, so they just stuck it in place and glued it. A new speedometer is like $90. Clean off the crud and plug your wiring into your new one.

The shifter can be adjusted for angle, but if there's looseness in it, I think that's internal.
I don't understand your rude comment one bit.

It was his landscaping trailer and there was no way to tie down or secure the bike, so I laid it on the frame slider. I was on the side of the road at night for two hours with no other option so I did what I had to do.

Not sure why the chain broke.

If I buy a new speedo won't the mileage be incorrect?
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post #4 of 9 Old 03-02-2017, 05:06 PM
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Quote:
Originally Posted by yoitschavez View Post
I don't understand your rude comment one bit.

It was his landscaping trailer and there was no way to tie down or secure the bike, so I laid it on the frame slider. I was on the side of the road at night for two hours with no other option so I did what I had to do.

Not sure why the chain broke.

If I buy a new speedo won't the mileage be incorrect?
A lot of people when they see an obstacle in front of them, flop the bike on it's side and crash. They say 'I had to lay it down'. They mean, 'I panicked, and instead of braking and bleeding speed I wiped out'.

I realized afterwards that you meant 'I laid the bike over to transport'. So yeah, what I said does not apply.

Yes, if you get a new speedo the mileage will be incorrect. You could get a speedo and pull the guts of your speedo and put it in the new housing. It looks to me like the plug, which is molded into the back if the housing, is the primary thing that isn't working.

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post #5 of 9 Old 03-02-2017, 05:12 PM
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The disconnected plugs in your fairing, the small black one has a plug already in it. It's a dead end. The gray one is your turn signal.

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post #6 of 9 Old 03-03-2017, 12:33 AM
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The ECU is that shit u see in the pic with the red/gold sticker on it.

That exhaust servo, u dont need it. Remove that shit. But that will turn on the red FI light. Contact our member Laggy311 and he can make u a device that plugs in and turns that light off. He sells em for cheap.

That red FI light is kinda like the "check engine" light on these bikes.

That orange wire not connected to anything, thats your tester wire for the FI light. It doesnt plug into anything.

Double check those sprockets...they look like shit from that angle.
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post #7 of 9 Old 03-03-2017, 02:01 PM
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Quote:
Originally Posted by Scorpi0 View Post
The ECU is that shit u see in the pic with the red/gold sticker on it.

That exhaust servo, u dont need it. Remove that shit. But that will turn on the red FI light. Contact our member Laggy311 and he can make u a device that plugs in and turns that light off. He sells em for cheap.

That red FI light is kinda like the "check engine" light on these bikes.

That orange wire not connected to anything, thats your tester wire for the FI light. It doesnt plug into anything.

Double check those sprockets...they look like shit from that angle.
Agree on the rear sprocket. It looks awful. Almost looks like some of the tips are broken off.
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post #8 of 9 Old 03-04-2017, 01:32 AM
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Yea, that sprocket looks bad. Replace both of the sprockets when you replace the missing chain.

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post #9 of 9 Old 03-04-2017, 08:03 AM
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Do yourself a favor and look into the bike even deeper because it was obviously not well maintained due to the cleanliness factor alone. I suspect that you have about 3 lbs of chain lube and debris under that front sprocket cover. I would also check the air filter and remove the airbox and check the plugs and everything else underneath it while you're at it.
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