My bike is running too much fuel and wont go! - Kawasaki Forum :: KawasakiWorld.com
 2Likes
  • 1 Post By ninjayorkie
  • 1 Post By ninjayorkie
 
LinkBack Thread Tools Display Modes
post #1 of 12 Old 08-09-2019, 10:01 AM Thread Starter
Junior Member
 
Join Date: Aug 2019
Posts: 5
My bike is running too much fuel and wont go!

I've got an 02 ZX12R A1 (2000/01 model) and I'm having a massive over fuelling problem. It been down the shop for 2 months now and we can not get it to run properly.

So far we have changed the entire throttle body, fuel pump, MAP sensor can position sensor and the TPS but the thing still will not run properly.

We know the engine itself is ok as we have done a compression test and everything came back ok and even, the coils have been tested with the spark plugs as well so everything is good there.

We have managed to make it run by disconnecting the pipe on the MAP sensor so it measures to atmosphere, choke on and the TPS round as far anti clockwise as it would go while still screwed in. It ran rich as hell but all 4 pots ran (proving the engine I guess) and you could rev it up but give it too much throttle too quick and it dies. Also, no matter where the TPS was, still ridiculously rich. Like so rich you can taste it. When its running, if you put the tube back on the MAP sensor it cuts out.

It's clear it's running way too much fuel and strangling itself but we cannot figure out why. Do I need to buy a new ECU for this bad boy or have I missed something?

P.S. all replacement parts were brand new kawasaki except the throttle body which came off another working bike. There are no aftermarket parts on this except some cosmetics and a scorpion exhaust (apparently made for this exact bike but the fault originally occurred with the stock exhaust on it anyway, all the unburnt fuel went down the exhaust and blew it up as well as melting some cowling hence the new one). Sorry for the long post but I really need help!
Jkirsopmaine is offline  
Sponsored Links
Advertisement
 
post #2 of 12 Old 08-09-2019, 03:00 PM
Senior Member
 
Join Date: Nov 2010
Location: detroit michigan
Posts: 2,502
I will get the ball rolling. Lol

Is the FI code light on?

Are the air cleaners dirty?

If you raise the tank, there is a air temp sensor in
the right side inspection cover. This can fail and cause a very rich condition.


Is the engine running on all 4 cylinders?

Does it run rich when it’s cold?

cmg

Last edited by color me gone; 08-09-2019 at 03:02 PM.
color me gone is offline  
post #3 of 12 Old 08-09-2019, 09:16 PM
Member
 
Join Date: Apr 2019
Posts: 84
I would replace the ecu of you can find one. You said an 2002 model, then you say it's an A1, which is a 2000 model. Which is it? The ecus are not compatible between those years. Let us know.
Jpowell490 is offline  
Sponsored Links
Advertisement
 
post #4 of 12 Old 08-09-2019, 11:03 PM
Senior Member
 
ninjayorkie's Avatar
 
Join Date: Dec 2004
Location: Altofts zx-12r B4
Posts: 1,390
Garage
Have you got the TPS plug and inlet air pressure plugs the wrong way round? this is easily done by accident because there so close to each other.
Duck00 likes this.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
ninjayorkie is online now  
post #5 of 12 Old 08-10-2019, 04:42 AM Thread Starter
Junior Member
 
Join Date: Aug 2019
Posts: 5
Quote:
Originally Posted by color me gone View Post
I will get the ball rolling. Lol

Is the FI code light on?

Are the air cleaners dirty?

If you raise the tank, there is a air temp sensor in
the right side inspection cover. This can fail and cause a very rich condition.


Is the engine running on all 4 cylinders?

Does it run rich when it’s cold?

cmg
Thanks for replying!

Fl code light is not on u less we force a fault by unplugging a sensor or something. So we know it works too.

Air cleaners are good, and the temp sensor has been swapped with another to check and it was fine.

IF we get the engine to go (very rare and difficult to do) it runs on all 4 cylinders but extremely rich, and we can not run it long enough to get heat in there anyway so yes, rich when cold.
Jkirsopmaine is offline  
post #6 of 12 Old 08-10-2019, 04:44 AM Thread Starter
Junior Member
 
Join Date: Aug 2019
Posts: 5
Quote:
Originally Posted by Jpowell490 View Post
I would replace the ecu of you can find one. You said an 2002 model, then you say it's an A1, which is a 2000 model. Which is it? The ecus are not compatible between those years. Let us know.
The bike is an 02 reg but an A1 2000 model. Sorry for the confusion.
Jkirsopmaine is offline  
post #7 of 12 Old 08-10-2019, 04:51 AM Thread Starter
Junior Member
 
Join Date: Aug 2019
Posts: 5
Quote:
Originally Posted by ninjayorkie View Post
Have you got the TPS plug and inlet air pressure plugs the wrong way round? this is easily done by accident because there so close to each other.
This is definitely a possibility as long as the TPS is a 3 pin plug. I cant check it right now as it's still in the garage and my mechanic is away this weekend but I do know for sure that the MAP sensor plug is 3 pins.

Can anyone confirm for sure how many pins the TPS has?
Jkirsopmaine is offline  
post #8 of 12 Old 08-10-2019, 06:54 AM
Senior Member
 
SteveW's Avatar
 
Join Date: Jul 2011
Location: Perth Australia
Posts: 1,209
Quote:
Originally Posted by Jkirsopmaine View Post
This is definitely a possibility as long as the TPS is a 3 pin plug. I cant check it right now as it's still in the garage and my mechanic is away this weekend but I do know for sure that the MAP sensor plug is 3 pins.

Can anyone confirm for sure how many pins the TPS has?
Yes tps has 3 pin

2006 ZX-12R B6F
Ohlins / TRAXXION Dynamics / NISSIN / HEL / Power Commander / Bear Racing / Akrapovic / BMC / Muzzy / Healtech / ERMAX / Helibars / GSG / R&G / NUI Racing
SteveW is offline  
post #9 of 12 Old 08-10-2019, 07:31 AM
rmk
Member
 
Join Date: Feb 2017
Location: Netherlands
Posts: 89
Garage
Not sure if it's the same for all models but the plug for the air sensor is grey and the plug for the TPS is black on my bike. (Yellow/white, blue/white and brown/black wires)
rmk is offline  
post #10 of 12 Old 08-11-2019, 03:44 AM Thread Starter
Junior Member
 
Join Date: Aug 2019
Posts: 5
So I think you guys have just saved me 150. It looks like the plugs were the wrong way round, my mechanic has swapped them and it starts every time now. It's still a bit rough, probably down to TPS being in the wrong place right now.

I'll keep let you know for sure some time in the week but thank you so much for all your help!
Jkirsopmaine is offline  
post #11 of 12 Old 08-11-2019, 04:45 AM
Senior Member
 
ninjayorkie's Avatar
 
Join Date: Dec 2004
Location: Altofts zx-12r B4
Posts: 1,390
Garage
Good to hear it was an easy fix.
Here are a couple of guides on how to set the TPS, I've not used either as I have an adaptor cable.

Setting the TPS
#25 Tamper Proof Torx bit (with center hole) needed.

There are 2 ways to adjust the TPS.
The first way is dynamically with the bike running.
Adjusting the TPS this way you don't need a digital voltmeter.
Each bike is slightly different and this may be a way to adjust for those differences without relying on a set voltage or movement amount.

1- Warm-up bike until the fan is starting to cycle, engine hot.
2- Loosen TPS adjustment screws.
3- Raise idle to 2000 rpm with the idle adjustment screw.
4- Move TPS until the highest idle speed above 2000 rpm is achieved.
5-Tighten down screws and readjust idle to 1000 rpm.


The second way is using a digital voltmeter. With a plug in adaptor, or
1)Take two 2" pieces of a strong THIN wire(I use .020 stainless safety wire) and back probe the terminals on the TPS connector. Slide the thin probe wire between the rubber seal and the TPS wire. This will not damage the wires or connectors at all. Go across the Yellow/White and Brown/Black wires with a DIGITAL volt ohm meter, set to DC volts.
2)Turn the ignition on and tap the TPS with your finger CCW till it gets to the desired reading of 1.16 Vdc. Don't ever use an analog voltmeter when dealing with any computerized cars bikes whatever. (analog meters are the ones with a sweeping needle indicator)
You can always return the TPS to the stock 1.084vdc - 1.086vdc setting if the change is not an improvement in drivability.
rmk likes this.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.

Last edited by ninjayorkie; 08-11-2019 at 04:47 AM.
ninjayorkie is online now  
post #12 of 12 Old 08-11-2019, 07:49 AM
rmk
Member
 
Join Date: Feb 2017
Location: Netherlands
Posts: 89
Garage
That the bike runs rough can be due the airsensor, it's likely busted now because you swapped the connectors around. Once you replace that it should run better. You can take out the air sensor under the buddy seat to replace it with, if it runs better you'll know you need a new airsensor for sure. After checking that adjust the TPS accordingly.

I made the same mistake too and found an used airsensor for like $8 online instead of a new OEM for xx the amount which worked perfect.

A few weeks back I adjusted my TPS with the instructions Yorkie posted, it was very easy to set it to 1,16v and it runs great after. I'd recommend trying that first and then the manual adjusting. Because if you know it runs well on 1,16v it's super easy to revert it back to that if the manual adjusting doesn't run the bike well.
rmk is offline  
Reply

  Kawasaki Forum :: KawasakiWorld.com > Kawasaki Motorcycles > ZX-12R

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki Forum :: KawasakiWorld.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome