Sketchy wiring on my 99 - ZX Forums
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post #1 of 43 (permalink) Old 01-21-2017, 05:13 AM Thread Starter
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Sketchy wiring on my 99

So, I bought this bike a few months ago. Knew it was gonna be a project ($500 for a mostly there bike, and all), but damn, it's starting to get annoying. Mechanical problems is no big deal. Need to rebuild and engine? I'm all for it. Trans is shot? No problem. Carb ain't acting right? Let's get after it. But this thing is becoming a wiring nightmare, and I haven't even started on it yet. At first, I figured something was up after I saw the questionable turn signal wiring, where the previous owner decided to run holes through the intake tubes to wire his front turn signals. Then the questionable wiring for the rears. Easy enough. Then the joke of a starter relay showed up upon dismantling the fairings.



And now, this...



Now, I'm not sure what this is called, because it looks like a TPS. Never seen one on anything carbed. How necessary is it for this thing to run?
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post #2 of 43 (permalink) Old 01-21-2017, 10:30 AM
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Sketchy wiring on my 99

The closest thing i can find in the book is throttle switch / fuel enricher solenoid valve
But thats on an N model.

What do u have?


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Last edited by keepitgreen; 01-21-2017 at 10:33 AM.
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post #3 of 43 (permalink) Old 01-21-2017, 10:43 AM
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Hell.
Is it a temp sensor?
Where is it mounted exactly


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post #4 of 43 (permalink) Old 01-21-2017, 11:05 AM Thread Starter
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It looks to be directly on the side of the carb. Once I can get this damned thing off, I'll take better pictures.

Also, picked up some fairings today, and the guy has a full wire harness also. Picking it up later.
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post #5 of 43 (permalink) Old 01-21-2017, 11:27 AM
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Sketchy wiring on my 99

U might have carbs that didnt come on the bike.




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post #6 of 43 (permalink) Old 01-21-2017, 02:16 PM
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I think they are non-oem Carbs.... I think i saw somewhere the latter zx9's had a TPMS.
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post #7 of 43 (permalink) Old 01-22-2017, 04:28 AM
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ITs a TPS I have one on my ZX9
This is not to be confused with TPS reports. That's ummmm thats my mmy mmy my stapler.

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post #8 of 43 (permalink) Old 01-22-2017, 07:20 AM Thread Starter
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Lol fahzazxr!

Yeah, after Lenny h made the mention, I looked it up. So, I take it, is not required for the 7r. This makes me a little happier. If I could find a way to incorporate it, I would. I've also been looking into doing the coil on plug conversion, but all I've found is people ask about it, then say "well, it's done". No walk-throughs, or list of parts. Just mentions of this and that. I need to replace my coils, anyway. Figured I'd just go that route.

Hopefully, I don't much more questionable "modifications"
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post #9 of 43 (permalink) Old 01-22-2017, 09:26 AM
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I'm thinking if you change over to a 98 or newer ZX9R wiring harness you could incorporate the TPS on those carbs. That would require a huge amount of work though. And possibly changing CDI, fuse box, etc.


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post #10 of 43 (permalink) Old 01-22-2017, 10:04 AM Thread Starter
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Well, that could be easy enough, since I'm changing the wire harness, anyway. But, no need to, as it would pretty much only help with spark timing in my case.

Anyway, some clues to what I'm dealing with, and more questions... And updates on what's happening.


Plastdipped the fairings and tank to cover the Betty Boop paint job





Now for questions:

Is this plate supposed to have a number on it?



Is the VIN and Engine number supposed to match, and does the engine number indicate if it's a P or N model?




Here's the TPS mounting, and what the carb is.




This is starting to look like a cluster fuck of a bike. Think I'm just gonna go ahead and tear it all the way down just to figure out what's going on.
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post #11 of 43 (permalink) Old 01-24-2017, 05:02 AM Thread Starter
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Got some things in last night.



Went and fitted them on.





Picking up the wire harness on Friday. If I can find my damned borescope, I'll check out the cylinders to see if I need to open the engine up or not. I've no idea how the thing was running in the past, but I'm pretty sure it was running like crap.
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post #12 of 43 (permalink) Old 01-24-2017, 10:19 AM
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My memory isn't perfect, but I'm pretty sure my 98ZX7R had had that exact same TPS and it was hooked up.

I can't swear, because it's been a while, but I'm pretty sure.

If it's like TPS on other Kawi's, it's feeding TPS data to ECU for spark advance.

If I'm muddying the waters, my bad, but I'm pretty confident...
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post #13 of 43 (permalink) Old 01-24-2017, 11:10 AM Thread Starter
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Thanks blakjack. Any info helps. I'm new to bikes with engines on them, so anything just about helps. It's odd how these bikes have been around for so long, yet the information available is just a patchwork of stuff that only a few guys know, and partial information across the net.
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post #14 of 43 (permalink) Old 01-24-2017, 09:42 PM Thread Starter
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Found this today. I'm thinking this could have been caused from toppling over... I hope.


Worked on the bike a little, today. Tried to pull off the clutch slave cylinder. Literally one bolt holding me up on the job. Had to pull my water pump just to get to the damned thing, and now none of my wrenches or sockets can get to it. Any advice on what you guys used?

Also, found my borescope. The tip barely fits into the hole, so I didn't get a great look in the cylinders. The cylinders I checked (1&4) looks to have a lot of oil in them. The plugs looked to be on the rich side, and they weren't really tight. But the bike did run on them. I'm suspecting ring issues. The bike has 17k miles on it, and I'm not sure if this is a normal thing or not.
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post #15 of 43 (permalink) Old 01-25-2017, 09:36 AM Thread Starter
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Confirmed. Zx9 carbs. So, may not need a TPS. Couldn't find a plug for them to go to. Decided just to start from the frame up. Checked the rest of the cylinders, and they're covered in oil too. Not sure if someone tried a marvel mystery oil treatment, or what.

Other than that, carbs look okay. I need to pull them apart though. Any advice or tips?
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post #16 of 43 (permalink) Old 01-26-2017, 01:10 PM Thread Starter
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Levers came in today. Boy, did I order all the wrong stuff thinking this bike would be an easy fix.

Last edited by Falkon45; 01-26-2017 at 01:21 PM.
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post #17 of 43 (permalink) Old 01-27-2017, 07:37 PM Thread Starter
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Some developments today.



Picked up the box of random parts, electronics, and tank for $60 today. Some piecesi need, most I don't, and there was a cool aluminum rear sprocket with cush drive, but it had broken teeth. I was heart broken.

Started pulling the carb apart, also.



Currently looking for info on how to tell jet size as I've never messed with a carburator outside of a lawnmower.

I'm completely lost with this thing. Learning experience, so far. Seems fairly clean so far, other than dinner dried gunk at the bottom of the float bowl.
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post #18 of 43 (permalink) Old 01-28-2017, 04:51 AM
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Sketchy wiring on my 99

Always good to have spare parts. Good score.

Search youtube for carb vids if you need to. Might find some answers.

Ive ran across "delboy's garage" a while back and like watching his stuff.




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Last edited by keepitgreen; 01-28-2017 at 04:55 AM.
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post #19 of 43 (permalink) Old 01-28-2017, 05:33 AM
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I really can't tell by the picture but does your needle have rings and E clip, looks to me like a jet kit was installed. Your jet sizes will be on the jets, you might need magnifying glass to see them the stamp is pretty damn small. Also take note that the jets in carbs 1&4 are the same and jets 2&4 are the same but not the same as each other. Stock mine where 165 outsides 160 inner so 1&4 165 and 2&3 160's. Hope this helps.

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post #20 of 43 (permalink) Old 01-28-2017, 05:50 AM
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For the serials I am not sure the engine and frame will match and the silver tag on the frame is just a badge that says Made By Kawasaki Heavy Industries.
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