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12R Refresh Project

13693 Views 148 Replies 12 Participants Last post by  SteveW
10
I've been a member of this forum for quite a while, and have read numerous great threads where people have done rebuilds or clean up projects.
Now its my turn!
These days I'm flat out with work, have a 3yo daughter to chase around and another baby due in about a month - I'm very time poor...
So I decided - I need a new project! 😆

Tire Wheel Fuel tank Plant Vehicle


Over the years I've accumulated a heap of spare ZX12 parts, just because they're becoming rarer and prices for good parts is just going up.
Last week I spotted a 2004 B3 advertised on Marketplace - not running and no registration, a bit rough around the edges with a "fried ECU". Well good for me, I happened to have a spare ECU and key/lock set in the shed. The AUS/EUR 2004-2006 ZX12's have a built in immobilizer, so you cant just swap the ECU out and have it running. You need a matching key for it to start up.

I met up with the seller, it seemed as if someone had lost the keys in the past and an attempt to hotwire the bike was made.
First I installed the battery/tray from my 06 bike.
So I plugged in my spare ignition switch and ECU, cluster turned on, but there was still a fault light flashing at me.
I worked out quickly that the original ECU wasnt fried (it was in a box) but what was fried was the immobilizer antenna unit that sends the key information back to the ECU. This had been removed and opened - I'm guessing as part of the hotwire job.
Passive circuit component Circuit component Hardware programmer Computer hardware Electronic component

I pulled the immobilizer antenna unit off my 06 bike and then the immobilizer fault codes stopped and the fuel pump primed. I wasn't too keen to fire it up yet as the fuel was pretty stale, and I was unsure what the tank condition was actually like.
Looking over the bike, I thought even if the motor was no good, I could probably make my money back by parting it out.
Its got a full Yoshimura exhaust system, Power Commander, carbon fenders, good Radial forks - etc etc etc
Title checked out ok, so after a bit of bargaining the bike was now mine.
I checked the oil and coolant, disconnected the Power commander, installed the fuel tank from my 06 bike and fired it up.
Seemed to be nice and smooth, no strange noises from the motor. A win I think!

Tire Wheel Fuel tank Plant Vehicle
Tire Wheel Vehicle Fuel tank Automotive lighting


Automotive tire Vehicle Motor vehicle Automotive design Automotive lighting
Tire Wheel Fuel tank Vehicle Automotive fuel system



Got it warm and dropped the oil. Also noticed the cam cover gasket is leaking a bit and making a mess, possibly the cam position sensor o-ring.
It had a 0004 oil filter - I haven't bought one of these since 2010, so that tells me the oil probably hasn't been changed for a very very long time.
Fluid Water Cylinder Drink Bottle


I had a look in the Oil for glitter, or any indications of metal - nothing visible to my eyes. I'll probably cut the filter open later for a look.
Fitted a new 0008 filter, sump bolt gasket and some fresh Aussie Penrite 10w-40 Synthetic Oil
Product Font Material property Fluid Wood


While I was doing this I decided to remove a bunch of little LED "show lights" that were on the bike. The fuse box was missing a couple fuses so I replaced them too. Tail light fuse was blown - strange...
I also pulled the Genuine air filters out, and checked the condition of the air box. Pretty clean. Replaced the filters with some cleaner low use OEM filters that originally came off my brother's old ZX12. Only other option I have here are BMC Race, but dont think this needs them yet!

Went to fire the bike up with the new oil. No go!
What? I hadn't done anything besides remove the LED's. I checked a few things, and nothing was out of the ordinary.
Fault code was showing Cam Timing sensor. Pulled the sensor out of my 06 and swapped them. Still no go.
Checked the wiring diagram in the Workshop Manual. Pin 12 on the ECU.
This is what I found -
Hood Electrical wiring Automotive exterior Motor vehicle Computer hardware

Obviously part of the hotwire job. Tried to inject power from the tail light to the ECU - this explains why the Tail light fuse was blown.
Reinstalling the fuse was sending a dodgy voltage signal to the ECU. I cut the wire and the bike started again!

Put the original Cam pos sensor back in with a new O-ring.

Got it warm and just checked the TPS voltages.
This handy adapter from NinjaYorkie makes an easy job of it!

Light Electrical wiring Gauge Measuring instrument Auto part




Not much else done. I've got to come up with a bit of a plan for it.
Fuel tank and fuel pump is probably the highest priority to get checked out.
But I'm thinking for now, change the leaking cam cover gasket - while I'm at it check valve clearances and change spark plugs and the figure 8 gaskets.
Radiator and coolant flush while I'm at it.
Needs a new battery and tyres and I've got a few little parts to chase up.
Then probably fork oil, brake fluid, and check all bearings.
Besides the Chinese fairings, its in pretty good condition. The carbon front fender and rear hugger are pretty nice.
I do have a complete full set of genuine 04 Candy Thunder Blue fairing's I can put on this bike.
It will make a nice clean street bike. My brother is already talking about buying it off me - he sold his 2006 ZX12 a couple of years ago when he moved overseas for work, but due to Covid he returned home and is missing his old bike. I'll have a think about that...

Stay Tuned!
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Btw Don, what radiator hose kit did you end up putting on your 12?
I'm looking at the AS3 kit
SteveW did u buy that AS3 hose kit?

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Bear
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Yes its on its way over to me!
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Every hose fit 100% - no cutt'in no slic'in.
Little tight under the Rad.Res.

Bear
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How does the AS3 hose kit compare to the SAMCO kit?
I also found the hose on the radiator/reserviour was tight, and was pushing the top of the fairing out slightly.
That's the one I reused the oem hose on.
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Cheers Gentlemen 🍹

I run the AS3 Performance hose kit in my bike. Hoses are a perfect fit... well all hoses fit perfectly accept the two hoses that go to the overflow tank. These two hoses are just to thick and was a more or less a kick to the dick to try and install them because there is not enough room for the hoses. So I reused the OEM hoses for the overflow tank.
I think that the AS3 are just as good as the Samco hoses. I have a Samco hose kit on my trackday bike (Honda CBR1000). I can't tell any real difference, both are high quality hoses.

/Tom
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I managed to mount all the hoses, it took some hours of rearranging to fit inside the fairing.
So I avoided "a kick to the dick", that's always a bonus. o_O

Bear
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Ooh, I forgot. When you assemble the hoses, specially the hoses going in/out of the rear of the engine. One needs to install the hoses and tighten the hose clamps in a specific order. If you don't, you will not able to tighten the hose clamps, because the hoses will be in the way/interfere and there is NO room, even if you have tiny hands. So to any one who is planing on doing this, remember in what order you unclamp and pull out the the hoses, then assemble the hoses/tighten the hose clamps in the reverse order... If you don't do it this way, well here comes the kick to the dick again... I learned this the hard way when I did this project, so pay attention.. 💕

/Tom
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Ooh, I forgot. When you assemble the hoses, specially the hoses going in/out of the rear of the engine. One needs to install the hoses and tighten the hose clamps in a specific order. If you don't, you will not able to tighten the hose clamps, because the hoses will be in the way/interfere and there is NO room, even if you have tiny hands. So to any one who is planing on doing this, remember in what order you unclamp and pull out the the hoses, then assemble the hoses/tighten the hose clamps in the reverse order... If you don't do it this way, well here comes the kick to the dick again... I learned this the hard way when I did this project, so pay attention.. 💕

/Tom
AMEN to that Brother ( except for the second kick to the ....) o_Oo_O

Bear
Thanks for the advice guys.
And looking at it, I think you'll even have trouble with the stock hoses if you dont reassemble in a particular order!
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No, haven't stopped yet!
I'm waiting on a few parts to arrive to continue reassembly.
Looks like I won't be riding it to Phillip Island this year, few things have changed for me at work and I can't get that time off!

Anyways, I re-inspected my front engine mount rubbers and they do need to be replaced. But Kawasaki says they're no longer available! Anyone know of some alternatives?
I've just checked on Ronayers site, they seem to have the dampers/rubbers for B3 on the microfiche, and testing it in the purchase cart it seems to be in stock.
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I've just checked on Ronayers site, they seem to have the dampers/rubbers for B3 on the microfiche, and testing it in the purchase cart it seems to be in stock.
Interesting, I'll have a look.
But my local dealer was also saying available, but when they tried to order it eventually said no..
Some time ago I compared the front engine hangers to the exhaust can hangers rubbers but I can't remember the differences, but it could be worth a look.
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Some time ago I compared the front engine hangers to the exhaust can hangers rubbers but I can't remember the differences, but it could be worth a look.
Exhaust hanger bushes are a lot smaller!
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I havent given up! Just been extremely busy, mainly with work and job role changes etc. Bike trip to Phillip Island wont be happening in October, so I guess some motivation to get this bike finished also slowed...

Still have a bunch of parts to fit and get things finished!
Gotta love when some of the harder to find NOS bits arrive..
NOS tank cover piece
Rectangle Electronic device Wood Composite material Auto part


Later B model TPS covers - which always tend to fall off. I usually place a strategical cable tie around the bottom part to stop this
Rectangle Font Auto part Fashion accessory Electric blue


CNC'd KLEEN block off plate kit. Local supplier had these in stock. This brand do 2 kits for the ZX12, early and late which have the ECU switched air valve. I went the early option as I've already made an eliminator plug with connectors I bought earlier to stop the ECU fault code being shown.
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Little spot of blue thread lock on the new stainless bolts and the block off plates are fitted.
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I'm glad that apart from me there are some frick's who are also reviving the neglected 12r - greetings from Poland.
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