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Discussion Starter #1 (Edited)
This is a ZX9R B2 that I just recently acquired

I was just warming up the engine, as I`ve been doing for the past three weeks daily or so I tried.
That`s because I got a left wrist injury.. so I can`t ride it for the time being until I fully recover and therefore I had no easy way to get some more fresh gas to it.

I mis-calculated the amount of gas remaining in reserve, so it ran out of gas prior to what I expected.
I was forced to get a fresh gallon and pour it in the tank but it didn`t want to start though.

Since I didn`t know the bike`s maintenance history (it`s a 31k mile bike so probably not that much of service records) I took that opportunity to refresh the main components to keep it running good and smooth so I disassembled the side fairings to check for small leaks, corroded grounds, pinched wires and hoses etc.

The tank came off of course and so did the airbox, carburetors, fuel delivery system, ignition coils and spark plugs.

- I Cleaned the carburetors, they were not badly dirty anyway so that was fast and easy, didn`t messed up with those that much.

- Fuel filter was replaced with a brand new OEM unit.

- Fuel hoses were also replaced to the correct spec and size.

- Spark plugs were just fine wire brushed cleaned and gaped correctly, they seem recently replaced but not gap to spec.

- Spark plug cables and ignition coils were cleaned and reinstalled.

- Electrical components such as the big white connector was inspected but left untouched. I was afraid to break it`s plastic ´clips´ or worse ....ask me how I know (MR2 brittle plastics)

- All airbox components were cleaned and the air filter was replaced with a brand new one.

So I lost nothing and I didn`t break a thing... It took some time, about a week or so a few hours at night but When everything was put back together it still didn`t want to start.

... The battery voltage reads close to 12.20V , it drops to 11.85V when I hit the start button, the starter kicks in and cranks the engine, everything sounds fine but it won`t fire up.

I then tried to jump start with the old Isuzu Trooper`s help (taking all precautions) and the peak voltage read out on the bike`s battery was just up to 12.55V after an hour of charge... it didn`t make a difference on the starting attempt.

I then inspected the fuse box, all fuses, close wires to it and the starter relay, fuse and connectors.

I haven`t taken the tank off again but I was able to confirm from the side that the fuel filter has gasoline in it, I haven`t check the pump though.

I haven`t done much since then, I`ve been just reading all Threads related to starting issues across all forums I can find but they all vary and differ from this particular case.

I did tried the clutch switch and the neutral position check. I also jumped on the bike with the clutch lever in and the rest stand up. Nothing.

Last night just for the sake of boredom and frustration I geared all up: Helmet on, jacket and gloves.. I sat in the bike and I pressed the start button hoping for nothing -It fired up!! ..but then it died just right after, but the engine ran for about 5 seconds at least, not smoothly though.

What can this be?
Voltage?
 

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A bit late I know but I don't often come into the zx9 forum part.

You need to do resistance checks through the kill switch, if this is slightly corroded you will lose coil voltage giving a weak or no spark.

Also you can put the bike in gear with the side stand down and press the start button, the bike should not turn over but you should hear the fuel pump knocking for a short time till the carbs are full. This will let you know the pump is working to prime the carbs. When the bike is running the ECU sends a plus to the 1-4 coil which also goes to the fuel pump relay giving it a bit of power to keep the pump ticking over.
 

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Discussion Starter #3 (Edited)
Thanks @ninjayorkie I've seen many of your postings and tutorials, you are really of a good help to have around, thanks!

I was able to solve the issue, it was bad spark plugs, two of them were not working so I swapped in all 4 new ones and the engine started to work as expected!

..That was about two or three weeks ago. And now it won't start again.
btw I didn't rode the bike since the spark plugs were replaced, I did run the engine every other day though. No issues at all.

I had to go out last night, it was mildly raining and very windy, I was being careful not to hit a puddle and fall into aquaplaning so I was riding slowy in 2nd gear when it suddenly bogged out and the engine shutted down, I tried firing in it up and it did but it went right up to 3kRPMs and then it died again, further attempts to restart the engine were unsuccessful until I pull the choke as it were a cold start.. it then fired back up to 3kRPMs again and after a few seconds I cut the choke out and engaged 1st gear, once more the engine died and not even with the choke on would start.

I was in a hill so I turned around and tried bump starting it in 2nd gear two more times without success..

Heavy bike to push back home, luckily I was still very close to my place.
I arrived very tired to troubleshoot so I'll do that today, any suggestions were to start once again?
 

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As the bike stopped when you put it into gear, I would check the side stand switch and its plug which is normally just above the front sprocket cover, also it might be worth checking the clutch lever switch.
There are picture guides on both of these at zx-9r.net
 

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Discussion Starter #5 (Edited)
Thanks again @ninjayorkie I checked all that and finally decided to pull the gas tank out and right there I found the issue: The gas tank petcock nozzle that connects to the fuel filter line somehow got separated from the assembly and aside from that when loose it somehow got pinched to that same line against the frame and the petcock perfectly sealing the line to the fuel pump.... yeah weird thing.. It at least prevented water from going in through that hose hehe.

The tank lost the rest of the fuel of course, I'm surprised how was I not able to smell the fuel vapors but yet again I was out on rainy and very windy conditions, the rear wheel had some dry fuel marks along with dissolved chain lube.

So there it is.. the weirdest thing it ever happened to me on a bike.
 

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Well thats a new one. :| Still, you have it sorted that's the main thing.:grin2:
 
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