ZZR600D1 wont rev underload beyond 7K rpm???

tony-uk · 07-19-2008

Hi guys, hoping someone here might have an idea??

ZZR600 will rev right round while stationary, but not beyond 7k rpm in any gear

it just givees up, no idea if its fuel or ignition

thinking its fuel, but carbs have been stripped rebuilt and cleaned etc, balancing is spot on, it idles sweet, and pulls hard in all gears up to 6500rpm, but then gets asthmatic, have to shut the throttle off in some instances to get it to run properly again, like up big long hills, is killing me not being able to get above 80mph on way to work of a morning

been throguh all electrical joints etc, replaced vacuum hoses and put sealant round them as well just to double be sure.

new plugs, changed the coils and leads for new/ones that are known to be good

new fuel, and at our prices it hurt to throw away the old

it has a motad nexxus exhaust system, and I have heard of flat spots, but this isnt a flat spot, you cant get through it no matter what you do, well ok it is a flat spot but 7k to 14k flat spot is a bit of a mickey take LOL

only things left I can think of are valve clearances??

would these play up in this manner?

a few people have said CDI but I need to be sure before replacing that, they stupid expensive and bought 1 for my zephyr 3 years back, it didnt work when brand new, but here in the UK you get no warranty, so thats a £390 paperweight for the garage!!!

LoudFastUgly · 07-19-2008

Mileage?

tony-uk · 07-19-2008

52k miles

engine is quiet and smooth, been well looked after, but must be into valve territory by now???

LoudFastUgly · 07-19-2008

Several times over!

Definately a valve adjustment is in order!

tony-uk · 07-19-2008

HMMM was hoping that wouldnt be the problem

not opened up these modern engines LOL, prefer my big old aircooled lumps

too many pipes and black boxes on these damned modern bikes

guess its time to find a manual for it and delve in

LoudFastUgly · 07-19-2008

same as a/c lump, more 'stuff' in the way. maybe you'll get lucky and it won't be shim under buckets.

tony-uk · 07-20-2008

been told its shims, so looks like 16 lots of measuring and checking is on the menu for a weekend soon

07-19-2008	#1 (permalink)
tony-uk Newbie Join Date: Jun 2008 Posts: 6	ZZR600D1 wont rev underload beyond 7K rpm??? Hi guys, hoping someone here might have an idea?? ZZR600 will rev right round while stationary, but not beyond 7k rpm in any gear it just givees up, no idea if its fuel or ignition thinking its fuel, but carbs have been stripped rebuilt and cleaned etc, balancing is spot on, it idles sweet, and pulls hard in all gears up to 6500rpm, but then gets asthmatic, have to shut the throttle off in some instances to get it to run properly again, like up big long hills, is killing me not being able to get above 80mph on way to work of a morning been throguh all electrical joints etc, replaced vacuum hoses and put sealant round them as well just to double be sure. new plugs, changed the coils and leads for new/ones that are known to be good new fuel, and at our prices it hurt to throw away the old it has a motad nexxus exhaust system, and I have heard of flat spots, but this isnt a flat spot, you cant get through it no matter what you do, well ok it is a flat spot but 7k to 14k flat spot is a bit of a mickey take LOL only things left I can think of are valve clearances?? would these play up in this manner? a few people have said CDI but I need to be sure before replacing that, they stupid expensive and bought 1 for my zephyr 3 years back, it didnt work when brand new, but here in the UK you get no warranty, so thats a £390 paperweight for the garage!!!

07-19-2008	#2 (permalink)
LoudFastUgly Got KZ? BTK Expert Join Date: Oct 2007 Location: Ontario Kanata Posts: 880	Mileage? __________________ KZ550A4

07-19-2008	#4 (permalink)
LoudFastUgly Got KZ? BTK Expert Join Date: Oct 2007 Location: Ontario Kanata Posts: 880	Several times over! Definately a valve adjustment is in order! __________________ KZ550A4

07-19-2008	#6 (permalink)
LoudFastUgly Got KZ? BTK Expert Join Date: Oct 2007 Location: Ontario Kanata Posts: 880	same as a/c lump, more 'stuff' in the way. maybe you'll get lucky and it won't be shim under buckets. __________________ KZ550A4

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07-19-2008	#3 (permalink)
tony-uk Newbie Join Date: Jun 2008 Posts: 6	52k miles engine is quiet and smooth, been well looked after, but must be into valve territory by now???

07-19-2008	#5 (permalink)
tony-uk Newbie Join Date: Jun 2008 Posts: 6	HMMM was hoping that wouldnt be the problem not opened up these modern engines LOL, prefer my big old aircooled lumps too many pipes and black boxes on these damned modern bikes guess its time to find a manual for it and delve in

07-20-2008	#7 (permalink)
tony-uk Newbie Join Date: Jun 2008 Posts: 6	been told its shims, so looks like 16 lots of measuring and checking is on the menu for a weekend soon

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