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2006 ZZR600 Bogs at half rpm but revs to redline in neutral

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bogging electrical zx6r zzr600
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318 views 2 replies 3 participants last post by  michaelpesch  
#1 ·
I have an 06 zzr600 (with yoshi exhaust) thats got an issue I cant figure out. I bought it from second owner recently, first owner let it sit for quite a while (multiple years) and second owner didn’t have it too long. I had a multitude of things replaced by my top local mechanic cause I haven’t really had the time: carbs were completely rebuilt rejetted and tuned, fuel pump and fuel lines replaced, throttle cable replaced, brakes rebuilt (not necessarily needed to mention), he did some other things but only really did things that needed to be replaced to get it near perfect. He tested everything under load individually; like the individual cylinders, pressure leak down, ignition coils, spark plugs, everything electrical, etc and it . It has 12,300 miles on it and the engine runs super strong, it absolutely rips to redline in neutral and sounds amazing, but when I ride it, once it reaches about 8k rpm in first it starts to bog down, 6.5k in second, around 5k in 3rd etc.

The mechanic said it has to be an electrical short somewhere cause he can’t really think of anything else it could be but them replacing the wiring harness would exceed the cost of the bike. I was going to replace the ecu and maybe take a look at the wiring, but does anybody have any thoughts at what else it could be?

p.s. sorry for the long post just thought I should post all details lol
 
#3 ·
It sounds like it was jetting incorrectly. Redlining in neutral/clutch-in requires basically no work for the bike, just spinning the internals around. Once you start putting the bike to work it requires more fuel naturally and if it's jetted incorrectly It will bog out.

Same situation for example a hair dryer. When you turn it on it requires a nominal ~10amps. But when you put your hand over the end you will hear it get louder and the amp draw will increase to around 15amps because you are putting a load/work on the machine and it requires more power to push warm air past your hand.

I HIGHLY suggest taking the carb bowls off, writing down the sizes, and calling yoshi exhausts.. or checking around on forums, and find what setups fellow yoshi guys use. Otherwise you can try shimming/adjusting the clip (depending on your setup) on the main jet needle and you will for sure notice a difference. Raising the clip up with lean and lowering the clip down will richen, you should try moving the clip one position down or adding a single shim to each carb. Once you do that change your plugs, coppers work great on these bikes, and take the bike out and ride it hard. After about 5 minutes of riding see if there is a difference, if there is keep tinkering.

Make sure the ram air is adjusted correctly as KevA noted, and ensure all the spark plug wires and firmly connected and arent falling off of the boots, that is a common issue on these bikes. But stuttering at mid-range rpm when under load is 1000% a fuel issue, check your fuel pump and make sure you dont stick a chinese one in there, they WILL NOT WORK ON THESE BIKES. I learned the hard way, used one on eBay or choke up the $300 for an OEM kawi one. Don't buy aftermarket fuel pumps
 
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