Question about 2003 kawasaki ZX-6R

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2003 Kawasaki ZX-6R bogs down at 5000rpm loses power

2003 Kawasaki Ninja 636 ZX6R. The bike has been sitting for about a year (didn't change the gas). The bike is NOT carbureted its fuel injected (getting injectors cleaned tomorrow). After changing all the gas, oil, and coolant the bike idles fine and in Neutral revs fine but when I put it in gear the bike gets to 5~6K rpm and bogs out regardless of the gear. No smoke out of the exhaust. Let it idle for about 2 hours with a potent fuel cleaner and still the same result. Checked all vacuum hoses (Good). Checked all electrical (Good). Has a longer fuel line we use on our lawn mowers(Pressure is still good and the inside diameter of the fuel line meets the specs for the bike just the length is longer) so the assumption is it's not the fuel line. Assuming it's not the injectors I need to know what's next on the list. I'm a DIY GUY so taking it to a shop other than mine isn't an option. @

Posted by Anonymous on

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  • kawasaki Master
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Hi, Anonymous engine "BOG" is mainly caused by a rich air and lean fuel condition but it can also be caused by a lean air and rich fuel condition this situation rarely occurs and is only caused by the misinformed weekend warrior that owns a toolbox. If the bike has been sitting for months or years you will have to completely disassemble the carburetor and submerge the parts (except rubber parts) in "Carburetor Dip" It usually comes in a gallon bucket with a wire mesh basket that can be purchased at any automotive store. If it is not the above scenario then the following explanation will apply.
The more you open your throttle the more vacuum you are creating in your carburetor venturi and your intake manifold. When you are operating at higher RPM any unmetered air that leaks into your system can become more obvious.
Unmetered air is air that is getting into your system after the fuel has been delivered. If you have unmetered air getting into your system between the butterfly/slide of the carburetor and the cylinder head this will create a lean condition.
All of the rubber components of the fuel system like vacuum hoses and intake manifold that you mount the carburetor to are made of rubber. If none of these components have been changed they are more than likely highly degraded and probably cracked in places to allow unwanted-unmetered-contaminated air into the combustion chamber. Check all of your vacuum lines and vacuum plugs for carburetor synchronization. The vacuum plugs are in the head just after the rubber intake manifolds. The petcock has a vacuum line as well as part of the emission system.
1. Check the intake manifold for fissures.
2. Ensure the bands used to tighten the manifolds down on the intake are secure and have not bound up the manifold.
3. Make sure air box fittings are not warped and fit completely over the carburetor.
Your airbox is metering air and is the first step in a process of consuming air and fuel. The system requires the resistance of the air filter in order to get the proper vacuum to "SUCK" the fuel out of the float bowl and create the proper venturi effect.
Improper mounting and sealing of the airbox will create a small lean effect. This might seem like no big deal but you are inviting dust and debris in your engine that is doing slow damage by not having proper fitment. Fix it so you know it's not contributing to your issue. Pick the low-hanging fruit first.
Do not go and start adjusting anything at this point. It ran fine before. There is something wrong with the assembly or a component. Do not adjust your floats. Get it back to where it was. The moment you start tweaking everything is the moment you lose OEM settings which are a must-have for fine-tuning and maximum performance.
Fine-tuning your carburetor and multi carb syncing come at the very end following the proper procedure established by the Carburetor Gods.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
03 636 bogs at 5000rpm KawiForums Kawasaki Motorcycle Forums
http://www.zxforums.com/forums/zx-6r-forum/29733-07-zx6r-high-rpm-bogging-issue.html
Kawasaki Ninja ZX 6R Service Manual
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Kawasaki Ninja Owners Manuals

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Posted on Mar 22, 2018

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Posted on Jan 02, 2017

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SOURCE: 2002 Kawasaki ZR-7S. wont rev up.

Check you main jets ccccccthey could need a good wiring through with needle wire cleaners or try running it without any air cleaner unit .If it runs well then could be an air filter problem.

Posted on Mar 14, 2010

sisadsl
  • 1508 Answers

SOURCE: I have a 1999 zx6r.

Check for damage to the kill switch(if it landed on the RHS)

Posted on Apr 02, 2011

dgriego7
  • 1 Answer

SOURCE: 2002 kawasaki zx6r bogging down

i got a 99 kawasaki and the reason it would bogg down like ur 2002 had to do with the vaccum system. there are 3 or 4 hoses that are connected to the gas tank, make sure they are connected in the right place and not crossed with one another. another place to check is on top front of the carburators. the hoses that connect there from the front of the bike cannot be torn and leaking. there is a simple diagram picture of the vacuum system under the seat of the ninja. these locations i have told u have been a problem for a carburated run 99 ninja zx6r

Posted on Feb 17, 2013

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