Electrical Gremlins. This one's tough... - Page 2 - ZX6R Forum
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post #16 of 22 Old 04-01-2017, 06:42 AM
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Best to download the shop manual for your bike, which has all of the wiring schematics in it. Then, you can start sorting out what has been done to that bike's wiring. I'm not convinced the wiring is related to the sensor being out of spec; but it's sure to be causing some other issues.

This is the very reason that buying a bike which is old enough to have passed through multiple owners is so typically an issue. The actual mechanicals are fairly sound -- unless someone gets in there and does something to 'improve' the bike. Electrical issues almost always come about due to owner mods.

Bikes are no where near as hardy as cars, with regard to their electrical systems. There is very little excess power, on a bike designed to be raced. Bigger alternators, heavier wiring, bigger battery..... all of that adds to the weight of the bike which cuts into performance.

Placing greater demands on the charging system will lead to earlier failures in the electrical system. Patching into the harness invites breaks in wiring (opens), corrosion issues, insulation break downs (shorts), etc.

"Basic stuff fellas. Use your head for something other than to break your next fall."

"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #17 of 22 Old 04-04-2017, 03:44 PM Thread Starter
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Update: The parts I ordered came in a bit early and I was able to get the wiring harness and TB assembly switched out and it seems to have fixed my problem for now. The bike rides a lot better at low speed/low throttle applications. The hardest part of the whole process was disconnecting the fuel line where it goes into the fuel rail since I was scared of breaking something.
Also lets play spot the difference between the new TB assembly (top) and the old TB assembly (bottom)

Yupp, I guess at some point in this bikes life, all the sub throttle butterflies were removed. I am shocked this thing still ran as good as it did.
Bonus pic: Something I have literally never seen before on this bike, the FI light off with the bike on.


And seriously, thank you all for the help you all have given me with fixing this problem. I'm still learning the intricacies of working on motorcycles.
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Relax...
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post #18 of 22 Old 04-04-2017, 04:38 PM
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Really glad you got it sorted.

Not sure if the FI will clear on it's own.. ON the Tiger 3 heat cycles no errors it clears the light. Code stays in ECU..
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post #19 of 22 Old 04-04-2017, 05:57 PM
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Congratulations.... that's got to feel pretty good.

The more you know, the better it gets.
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"Basic stuff fellas. Use your head for something other than to break your next fall."

"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #20 of 22 Old 04-05-2017, 08:47 AM
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Quote:
Originally Posted by ProZach View Post
Also lets play spot the difference between the new TB assembly (top) and the old TB assembly (bottom)
It looks like the old one had the secondary butterflies removed.

Edit: LOL, now that I read the rest of your post, I see that you mentioned it already.
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post #21 of 22 Old 04-05-2017, 08:50 AM
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And seriously, thank you all for the help you all have given me with fixing this problem. I'm still learning the intricacies of working on motorcycles.
Glad you got it all fixed!
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post #22 of 22 Old 04-09-2017, 05:40 AM
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I would still go into fixing the wiring harness of the bike. Dude the previous butcher that had the bike did a very bad job with the wiring. That will cause a problem in your bike in the future.. Dont go buy a new harness. Just repair and fix this one. Buy cables etc and start from scratch.looks good with the throttle body replacement. I know for a fact that the 05 with the secondary butterflies removed is not as good at performance as when it runs with the secondary butterflies on to it..
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