ZZR 600 problem

Brotheroak · L Plate Warrior Joined: 25 Jun 2004 Karma :

Hi all - first post - be gentle Wink

I have a ZZR600 E2 model. It has just started to run badly - sounds awful (possibly only firing on 3 cylinders) - thought it was a holed exhaust but couldnt find a hole, and the exhaust is only a few 000 miles old.
Starts no problem
Sounds horrible
Gets to high speeds (100mph+), but often takes seconds to react to any throttle, and even then it jerks as the speed increases (fourth cylinder kicking in and out?)

It was serviced pretty recently, ran okay for a couple of weeks (few 100 miles, and then this problem started (after not using it for a few days - left out in sun and rain). I have travelled over 90 miles (2 x 45 mile journeys) since the problem started and it hasnt improved.

I want to check a few basic things before taking it in to a garage to be looked at. Unfortunately most of my tools, and my Haynes manual, are currently in storage, so I have limited resources at my disposal. Also, although I have taken apart other bikes in the past, I have barely touched this one so am unfamiliar with the engine layout under the tank.

I have a couple of questions I hope you can answer:
1. Other than possible dodgy spark plug or HT lead, what else could be causing this problem?
2. How do I (easily) get at the spark plugs / HT leads?

Sorry for the long post, but I guess more information is better than less!

Zx6man · Nova Slayer Joined: 30 Apr 2004 Karma :

I had a d model and its just a tank off job to get at the plugs. could also be a kinked breather pipe from the tank, causing fuel starvation, On mine this went under the seat from the back of the tank, and sometimes it can get trapped in the seat.

It can also be crap in one of the carbs, making the needle not sit correct. If it starts ok then this is a possiblity, as it uses different jets to start.

Brotheroak · L Plate Warrior Joined: 25 Jun 2004 Karma :

Thanks for the reply.

I took the tank off but there's a nice big airbox beneath it, preventing access further. I thought about taking off the airbox, but that would mean disconnecting from the carbs (didnt look simple) and I didnt want to start that at 9pm, in the rain! Was hoping for a simpler solution!

I did check the breather pipe (thought it could be a fuel problem too) - seemed okay (but will recheck)

McJamweasel · BCF Junkie Joined: 22 Mar 2002 Karma :

To check if it is running on 3, run it for a little while and then see if all the exhaust headers are warm. The cold one is where your problem is.
____________________
BCF: Be yourself, just don't be an arse.

Zx6man · Nova Slayer Joined: 30 Apr 2004 Karma :

airbox should just sit over the carb throttles. undo top, take out filter then there are a few screws to remove airbox. It is fairly straight forward.

clemsta · Scooby Slapper Joined: 29 Apr 2004 Karma :

Probably just a duff sparkplug from when they serviced the bike, have you checked that the HT leads are on properly. To check the HT leads start the bike and take one off at a time, if it is sparking then it is fine, put it bck and try the next one.

Hope this helps

Adam

Brotheroak · L Plate Warrior Joined: 25 Jun 2004 Karma :

Thanks for all the help. Took a look at the weekend - HT lead 1 was arcing across to the engine block - I just had to clean up the connection and it was all fixed - if it happens again I'll replace the HT lead, but at least I now know how to get at the plugs!

Thanks again for the help Smile