Still Big Problem 636 7500rpm bog/misfire - KawiForums - Kawasaki Motorcycle Forums
 
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post #1 of 8 (permalink) Old 01-23-2013, 09:52 AM Thread Starter
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Still Big Problem 636 7500rpm bog/misfire

Greetings from Turkey,

I ve 2004 Kawasaki zxr 636,

Here is the video about the problem of my bike ;

I think motorbike interrupts ignition when it reach 7,5k rpm.

Details of Problem;When the Bike is in Neutral it s more clear meanwhile when i ride and each gears i ve the same problem which is bike is not gettin up from 7k rpm and stock there,s got strange voice at that rpm meanwhile electrical function ok all the lights on at indicator.

-If I push full throttle bike goes up to 15 rpm easily but when i throttle slowly then it s stock at 7rpm and do not get up to 14k
-When I reduce rpm such as from 14 rpm to down it reach 7,5k it s gettin stock there and got strange voice like 'tırrrr' and after from the exhaust 'pat pat pat'
-Sometimes when the bike is on first or second gear when i push full throttle rearly it s gettin up to 7,5 k but really hard.
-Out of these when i ve first realized that problem it was not so often happenin,day by day it has been gettin worst and since 3-4 months bike always stock at 7,5 k rpm.
-I guess my bike interrupts ignitation at spesific rpm which mean 7,5k,I mean something sends signals on ecu that you must stop ignitation.
Here What I ve done for fixin problem so far;
-Ram air,and Air filter checked
-Tried without air filter,no point.
-Vacuum pipes and air filters pipes checked
-Stand switch Deactivated
-When bike had the problem i ve realized 51.problem code,which means,Problem located in the area where 1.cylinder,pulser coil.In the manual it mentions that coil installation may harm,then i ordered new original coil and changed it,but didnt work somehow i still had the problem.
-Then I ordered full installation of coil and changed but still no positive result.
-Ordered original sparks and set it up no result
-Some people had problem about ignition key then i used my original key
-Changed fuel pump,and fuel filter(twice)
-All The sensors in the Injection systems (Tps and others) controlled by device they said no problem.
-Crankshaft sensor , Camshaft Position Sensor which located on ignitation system may have problem ?
-Other ignitation systems (Sparks,coils,pulser coil socket and installation controlled) no problem

After all the 5-6 months-period and no result,I spent a lot of money and time but wasted,Now I am stocked like my 7,5k rpm no way out,either i cant sell buy and i cant fix problem.I ve lost hope you to help me about the problem on my bike.
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post #2 of 8 (permalink) Old 01-23-2013, 01:05 PM
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Have you checked to see if the fuel injectors are clogged? If they're spraying in a crap pattern instead of the cone they should when clean, it could deoptimize the air/fuel ratio.
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post #3 of 8 (permalink) Old 01-24-2013, 04:02 AM Thread Starter
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Yes , I checked.Still have a problem.
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post #4 of 8 (permalink) Old 01-24-2013, 10:22 AM
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Checked your timing?

After that I'd check your compression, I doubt it, but there is a chance that at low throttle positions one or more of your valves is hanging open and screwing up your ratio the cylinder misfires, while at higher throttle positions it generates enough pressure to slam the valve shut and have the engine run properly.
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post #5 of 8 (permalink) Old 01-25-2013, 10:22 AM Thread Starter
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Originally Posted by Steel View Post
Checked your timing?

After that I'd check your compression, I doubt it, but there is a chance that at low throttle positions one or more of your valves is hanging open and screwing up your ratio the cylinder misfires, while at higher throttle positions it generates enough pressure to slam the valve shut and have the engine run properly.
How do check my timing ?
Crankshaft sensor ?
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post #6 of 8 (permalink) Old 01-25-2013, 05:47 PM
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It's a visual check. You have remove the crankshaft sensor cover and the valve cover. Then position the crankshaft so cylinders 1 and 4 are at TDC, then visually check the position of the marks on the camshaft gears to make sure they're in the proper position. One is pretty easily visible, the other requires a mirror to see, and it's rather annoying. While you're this far dug into the engine I'd suggest just going ahead and checking your valve clearances and checking the compression on the cylinders afterwards.

The process is much better described in the service manual, available here for download:
ZX636-B1_B2.pdf
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post #7 of 8 (permalink) Old 05-06-2018, 04:03 PM
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Any solution on your problem?

Kawasaki Fan
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post #8 of 8 (permalink) Old 05-18-2019, 04:34 AM
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check the barometric pressure sensor and your vacum lines check the vacum on the throttle bodies that attaches to t on the pair valve plumbing

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