Ok... sorry for the delay, but I jacked up my gas tank yesterday because I was impatient and didn't read how to take my tank out the right way. (some great tutorials are out over at: ZX-6r Wiki. At any rate, all you have to do after you undo the 4 bolts (2 under ur seat and 2 visible by the handle bars) is pop out the screw in the black shaft where your Off/On/Res is... Don't try to dismantle it the way my stupid ass did:
Exhibit A:
Disclaimer: This is what I did to my bike. It worked for me. I cannot guarantee that you will achieve the same results. I hereby absolve Kawiforums and myself from being liable for anything that happens to your bike from this point forward.
You will need some mechanical skills in order to get the job done.
the part number of the temp sensor that I used is: 21176-1120 or here is the visual rep since I don't read much:
I found it over at Ron Ayers.com under the "fuel injection" section. Yea, I'm still scratching my head about that one too...
So... Moving on. Here is what I did in a nutshell. I took the old temp sensor apart, used it's threads to thread back into the engine block (so I wouldn't have to retap the engine) and made my own brass coupler with some solder, flux and a torch.
So first, let's identify where the sensor is in the block and where the wire that goes up to the 636 gauge is:
1. Remove your gas tank.
2. look on the "driver side" for the plug:
Here is a side by side shot of the 2 plugs.
As you can see, the new sensor is alot larger and the threads are coarse, vs the original ZZRs fine threading...
After removing the stock sensor you may notice that your new sensor has 3 connections as opposed to the stock one which has 1... I went ahead and tested the three individually, and the bottom one (it was a different color on mine) which was Silver seemed to be the one that gave the temp readout.
Then I soldered a wire to the silver connection and used heat shrink on it to keep water out (from getting kicked up from the road).
this part can be optional for you guys, if you can find a coupler that can fit the original and 636's 1/4" sensor in it. What I ended up doing was opening the old temp sensor and only keeping the threading from it:
I then found a 1/4" brass coupler that went to I Think a 3/8", but I cut that piece in half and only used the 1/4" side:
I wasn't sure what size the original ZZR's temp sensor was so that's why I kind of did a Dr. kevorkian (see next picture) to basically make my own coupler. If you can find a brass coupler that has a ZZRs size (not sure on actual measurement), plz let me know, to a 1/4" coarse thread you're in business.
cue the kevorkian clip please:
Lastly, I soldered a crimp-able end onto the new wire that I attached to the new 636 sensor. then I crimped it to make sure it wouldn't come out. I did this to use with the stock wiring, you can splice it in if you so feel the need so you wont have to make another end like I did.
Hook the new wire on and ur good to go. Hopefully you'll see this after all that hard work:
Hope this helps the people who were wondering how to do this...
keep us updated
