[olajoe808]

Here's what i found on my bike. When i replaced the oem rearsets and installed aftermarkets I had to adjust the brake switch. When doing that the running voltage climbed. Now after installing a ram mount and with the phone charging while running the volts are back to what it was previously. At 29408 miles my electrical system is original, including the 18 year old battery.

 

[Mr ZX]

If the zx6r electrical system is anything like the zx12r one, which it seems to be given your problems, then it can still be a recurring problem - nothing that you've done wrong.

I have posted a fair bit on my fixes for the zx12r (with lots of advice and help from smarter people here!), and from a bike electrician here in Sth Aust.

Main problem - and this doesn't happen to all 12's - is that the heat/electrical energy generated by the Alt/Stator system overloads the stator wiring causing that to cook. Then there is either an oil wicking to the stator/reg connector or just heat melting or both to the connector. The bike electrician said the Alt puts out too much juice, and when the bike is stopped after a ride, say at a cafe, then there is no more oil cooling of the stator, then acts as a heat sink causing the stator wiring to cook and so on. His fix is to re-wire the stator with a LOWER gauge wire so as not to take on so much juice from Alt. Also I had a Japanese MOSFET reg/rec installed and different connectors etc.

Electrician said this is not a permanent fix but may delay the same happening again - and in my case it did couple of years later - but he fixed the stator again under warranty!

Others here have not had the same level of problems and seem to get away with just re-doing the stator/reg connector.

Good luck!

Don.

I'm not sure if the zx-6r has similar electrical system as the zx-12r, because for the zx-9r it's also not quite the same as the zx-6r according to ninjayorkie.

Sorry, yes, get a 3 way connector. I'm sure you'll find them cheap enough on ebay.

It won't matter which yellow wire goes where.

On the zx9 its a 6 way connector, but with 5 wires in, 3 stator, neutral and cylinder head temp.

 

[ninjayorkie]

Most of the zx's are similar in operation, thought the plugs used may change.

I'd go for a new plug again, just make sure the contacts when the plug is together are good.

After replacing the plug, you may want to disconnect the regulator and do some internal diode checks.
If one has gone short or open, you could still get 12+ volts output, but either one yellow wire will be pulling lots of current or 2 wires will be pull more than they should.

 

[Mr ZX]

I replaced the connector and ran some diagnostics. The rectifier diodes only gave an ohms reading when they should, however these readings were (I reckon) very high around 740 (this was in the up to 2000 K ohms reading range of the multimeter because in a lower range the multimeter gave no reading because it was too high).

So I guess i need to replace my rectifier?