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Old 12-18-2012, 04:53 PM   #1 (permalink)
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Unhappy Have i broke my ninja?

Hi guys im completely new to posting on forums but have always watched to see others problems and solutions. Unfortunately now i have my own..

Ive been riding a few years and now onto my biggest bike so far. My ninja 636 2005 c1h model.

The bike was restricted to 33bhp when purchased. Tonight i had her apart (this is were it all got technical)

After removing seat, tank, and air box. I've removed a throttle stop and washers from the air in take. ( during this process unclipped alot of cables but im sure ive put them all back correctly )

Rebuilt the bike. Started her up and 'vvvrroom' she immediately sound much louder.. But smelt richer.. Took the bike up the road to check all was fine and to my knowledge she was ( alot quicker tho ) brought the bike back. Turned it off with a grin on from ear to ear. ( this is were it went wrong )

Started the bike again 5 mins later and it started reving itself .. For instance it went/goes from 2k to 3k revs very quick repeatidly for 3 to 4 times then sits at 2k or 3k.. Were as before she sat nicely at 1.5k whilst idle.. the air being blown out the exhaust is hot ( i no exhaust fumes are hot but this gets ridiculously hot in no time at all ) she smells very rich and is popping, as it was miss firing? It also dosnt sound right, its not a knocking noise but more a very quick ticking noise. Not too loud but noticable. I have tried adjusting the idle twisty thing ( lol ) but wont go under 2-3k revs..

What have i done wrong? Missed a connection? Ht lead? A hose? Im so confused. Hav'nt stripped her back down yet to look. Could it be to do with the ecu?

Anyway. Anyone who gets back to me i would be very very greatful.

Only Mods is Laser exhaust system but that was fitted whilst restricted and has been fine.

Sorry about any bad spelling. Not the brightest spark when it comes to litracy.!

Thanks, Sam.

Last edited by Sam_636; 12-18-2012 at 05:00 PM.
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Old 12-18-2012, 05:27 PM   #2 (permalink)
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Check your idle. You can adjust your idle by twisting the knob on the left side by the frame that is by the knee


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Old 12-18-2012, 05:49 PM   #3 (permalink)
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You're not going to find shit until you tear it down again. Go over the hoses again, very carefully.
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Old 12-18-2012, 05:58 PM   #4 (permalink)
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Its not the idle, it wont let me adjust it any lower. Also with hoses? Could it be that? Ill open her up tomorrow and go over with a fine toothpick. Any other suggestions. A friend has said it could be the ecu? The dealer who restricted it remapped it. But surely to restrict it they would have programmed it to use less fuel as there for less air intake. And with injection you cant restrict the fuel? So why am i getting too much cause it reaks rich. And pops where fuel isnt burning. Mmm would it be worth me taking it to a kawa dealer? Would they open her up to see if i have missed something or just plug into a diagnostics machine? Thanks again.
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Old 12-18-2012, 06:25 PM   #5 (permalink)
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Knowing what you've done to it recently, the dealer will open it up. You can do that yourself. Go back in there and take a look before you get all fired up about what "might" be wrong.

Check EVERYTHING !
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Last edited by locknload; 12-18-2012 at 06:51 PM.
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Old 12-19-2012, 01:11 AM   #6 (permalink)
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I'd put money on it that you have a vacuum leak somewhere. Again make sure you put all of the hoses back, all of the cables back, and make sure you get a good seal on your airbox, throttle bodies, etc.
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Old 12-19-2012, 01:42 AM   #7 (permalink)
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If you don't have one already, get the service manual.
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Old 12-19-2012, 05:31 AM   #8 (permalink)
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Also just a query, round the air box and intake was some jubilee clips holding the restriction washers in the rubber connecters. I have removed them when re building as i thought they were only there to holding the washers in. Should they be in the even tho the washers arnt?
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Old 12-19-2012, 01:20 PM   #9 (permalink)
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ALL FIXED! Thanks everyone, it was a hose. Main link vacume pipe to throttle bodies. Obviously come lose whilst fitting the air box as last time i took throttle bodies and airbox off in one. This time fitted throttle bodies then air box. Problem solved. Now shes ready to rip if we had some good weather.
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Old 12-19-2012, 01:25 PM   #10 (permalink)
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I'll send you a bill...
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"Blah blah my bike is faster than yours around a technical track". Yawn. Well I on my feet can beat your small bike in a race of 100 laps around my couch
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