Zx12r Wont Rev Past 7k - Kawasaki Forum :: KawasakiWorld.com
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post #1 of 21 Old 10-27-2018, 05:00 PM Thread Starter
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Zx12r Wont Rev Past 7k

So i just got a zx12r and i test drove it and it seemed good but i couldnt open it up because of city traffic. Got it home, pulled the clutch in while riding, went to rev it, and it revs to 7k and dies. Went back home and investigated. Rpms drop to almost nothing and it revs back up and dies again. It wont go above 7k at any throttle position it only dies and revs up again at near WOT and WOT. The more throttle i give it the more it surges.
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post #2 of 21 Old 10-28-2018, 12:17 AM
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Do a search for fuel pump....it's all on here just look for it.

*** ZX12-R ~ RT2 360 ~ XR650R ~ DT175MX ***
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post #3 of 21 Old 10-28-2018, 03:13 AM
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Hi welcome and what mod year is your 12 as different pumps for diff years yes sounds like fuel pump/filter problem Craig

if anything goes wrong check the battery
no longer a rider but still an enthusiast
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post #4 of 21 Old 10-28-2018, 11:51 AM Thread Starter
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This bike is a 2002 zxr12r.
19000 miles.
Power commander
Muzzy exhaust
Its pretty beat, plastics are really bad.

The previous owner said he replaced the
fuel pump, battery, rectifier, and did the stator fix

Okay i have driven it around some more today. i started it up and it started and rpms dropped really low, like 600 rpm and it died. Started again and it started normally with the high idle lever all the way on. Then as it is idling i am getting my gear on and it dies (maybe 1min of idling) Start it up again and after maybe 10 seconds of idling it starts to die, but i give it some throttle and starts to idle again. It kinda sound like its loading up at idle.

I rode it around and it does not want to go above 4.5k rpms in any gear. The more throttle i give, the more it dies. At wot its like i turned the ignition off.

I can get it to go about 60-70mph indicated and thats with very light throttle.
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post #5 of 21 Old 10-28-2018, 11:53 AM
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I'd take out the PC first and see if that does anything.
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post #6 of 21 Old 10-28-2018, 12:26 PM Thread Starter
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I'd take out the PC first and see if that does anything.
There isnt any connector i can see just a bunch of wires wrapped up. Should i just snip the wires?
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post #7 of 21 Old 10-28-2018, 01:02 PM
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Quote:
Originally Posted by Zx12r97 View Post
Quote:
Originally Posted by rmk View Post
I'd take out the PC first and see if that does anything.
There isnt any connector i can see just a bunch of wires wrapped up. Should i just snip the wires?
Do not snip any wires.

Read the thread about power loss that is below yours. The guys here did a great job.

Are you just kidding with the "snip wires" remark?

cmg
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post #8 of 21 Old 10-28-2018, 01:06 PM
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The PC should be connected by plugs as far as I know. I wouldn't start cutting into the loom, at least not if you aren't very known with electrics. But if it isn't connected with plugs, a la plug and play, then I wonder what the PO has done to the bike. And maybe there's a fault in the wiring some where causing issues. You say it's pretty beat, just how beat?
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post #9 of 21 Old 10-30-2018, 12:01 AM Thread Starter
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Well today i took the fairings off to look for the pc connection only to notice a big ole crack on the frame. Looks like someone patched it and it didnt hold. The other side was rewelded and is starting to crack as well. Luckily i am a welder so i can reweld it, but i am not sure about taking the bike apart yet. Looks like i got screwed over. This is going on the back burner for now. Thanks for the replies.
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Last edited by Zx12r97; 10-30-2018 at 12:06 AM.
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post #10 of 21 Old 10-30-2018, 01:42 AM
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Sh!t thats not good !!!!!
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post #11 of 21 Old 11-02-2018, 04:35 AM
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https://www.kawasakiworld.com/zx-12r...8000-rpms.html
Hi, my problem was a dirty pump filter. Not sure if you have the same problem...
Good luck.
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post #12 of 21 Old 11-08-2018, 01:40 PM Thread Starter
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Finally got a manual in the mail yesterday, So today i took off the gas tank and checked the fuel pump. The Manual says 83mL of fuel for a 3 second prime. Mine pumped out a little dribble that consisted of about 10mL. So thats definitely (one of) the problem. The gas also seemed to be cloudy like there os some water mixed in. I looked online and the fuel pump is $238.. I dont think the po replaced the fuel pump like he said he did, at least not with a new one. I also found that one insert for the airbox is missing (see picture) . Definitely not good, who knows how long thats been missing.
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post #13 of 21 Old 11-08-2018, 11:28 PM
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Maybe contact the previous owner to see if he has the parts (fuel pump & airbox cover) sitting around?

Hopefully he does as it would save you a bit of money!

Good luck!

Don.
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post #14 of 21 Old 11-09-2018, 02:47 AM
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You've definitely got fuel problems. Most people in your situation always assume they need to replace their fuel pump when thats not the case. You most likely have a clogged fuel filter and not a failing fuel pump. Now the way I see it you have several options: you can replace with a new fuel pump assembly at close to $600 US or replace with a used ebay one at around $200 US witch will probably have the same issues. You can back flush your filter, but doing this will just be a temporary fix and you will be doing it over and over. Some people have been successful in cutting the filter housing and removing the element and sealing it back up good luck with this one. You could replace the filter, only problem is kawasaki doesn't offer just the filter for sale, but Suzuki does. This happens to be the same filter in the 99-07 hyabusa and 04-09 Vstorm. These filters go for around $200 US still a little pricy, but cheapest real fix IMO. Now having said all this you still have more important issues like making sure your bike is safe and roadworthy. The frame damage really should be addressed well before you get it running. If you need parts I have a good lot of parts feel free to PM me. Good luck your project.
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post #15 of 21 Old 11-09-2018, 07:33 AM Thread Starter
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Originally Posted by MetalMagician View Post
You've definitely got fuel problems. Most people in your situation always assume they need to replace their fuel pump when thats not the case. You most likely have a clogged fuel filter and not a failing fuel pump. Now the way I see it you have several options: you can replace with a new fuel pump assembly at close to $600 US or replace with a used ebay one at around $200 US witch will probably have the same issues. You can back flush your filter, but doing this will just be a temporary fix and you will be doing it over and over. Some people have been successful in cutting the filter housing and removing the element and sealing it back up good luck with this one. You could replace the filter, only problem is kawasaki doesn't offer just the filter for sale, but Suzuki does. This happens to be the same filter in the 99-07 hyabusa and 04-09 Vstorm. These filters go for around $200 US still a little pricy, but cheapest real fix IMO. Now having said all this you still have more important issues like making sure your bike is safe and roadworthy. The frame damage really should be addressed well before you get it running. If you need parts I have a good lot of parts feel free to PM me. Good luck your project.
I thought the filter is included with the fuel pump assembly? If so wouldnt replacing it take care of the filter issue as well? Im going to rinse out the tank because i think it may be dirty. If i can get the bike to run well then im going to fix the frame. I figure theres No use fixing it if i cant get it run anyway

Last edited by Zx12r97; 11-09-2018 at 07:36 AM.
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