Just re-wired the charging system. 2nd Regulator / rectifier unit replacement
I’ve had charging issues with Green Magic. Recall that was the first major problem of this bike, it would eat batteries.
I’ve cut out crispy wires and trimmed back charred wires that hook into the regulator / rectifier unit now twice. Both times I got some good life out of the charging unit – the first time I swapped in a low mileage ZR7S R/R unit.
The second repair job last year I cut back the wires again, but I knew it was only a matter of time…
The final day I was out west again, the bike was not charging riding and about to die soon I could easily tell. I throttled the bike at high rpms back home. And parked it and drove the van that day and flew east the next day.
6 weeks later I got back to the bike and took of the rear left panel, expecting to see fried wires at the R/R again. Which I did find. BUT, this time I also found a melted stator to regulator wires connector. That’s new and bad.
So I rounded up some new wire connectors and cut up some brand new THHN stranded 10 gauge wire and ran them from the stator connection all the way to the R/R and put new connectors into the plastic 6 pin clip there as well.
I cut back the 3 yellow stator wires a little bit and put on new connectors there and connected to the new 10 gauge wires.
I also installed a low miles ZR7S R/R unit, the same Shindegen Shunt unit from a different Kawasaki. I found it on fleabay for $13 shipped and couldn’t say no to that!
Result? Green Magic fired up (Although grumpily after sitting for 6 weeks with a weak battery. I had to push it up the hill to the crest and then bump start it down the hill after 3 sessions of trying to battery start.)
It ran rough for several minutes, but when it warmed up it ran strong and great!
A few days later I took it on a 80 mile run and it was great. I hope this solves the charging issues for a long time!
Posted in repair, Uncategorized and tagged Kawasaki, Ninja, regulator, ZX-6, Zx6e, zzr, zzr600 by green
Fuel hose Fuel Line size diameter 8mm I.D. 13mm O.D.
I’ve spent a lot of time searching for this info and finally figured it out. It’s hardly disclosed really anywhere.
ZX6E / ZZR600 use 8mm I.D. (Internal Diameter) fuel line / hose, with a 13mm O.D. (Outside D.)
In a pinch you could substitute 5/16″ hose as that seems to be much more common. You don’t need the common really thick auto parts version as that is used for higher pressure F.I. motors and we don’t need the thicker reinforced walls for carb low pressure fuel. Worm
One suggestion, Parts Unlimited makes a clear blue tinted fuel hose that is 5/16″ and they say long lasting and chemical / fuel resistant and fairly kink free (I think it’s polyurethane based). I got sold some 1/4″ Parts U. from the local Kawasaki dealer for my bike (wrong stuff – too small), and I have crammed it on, but it’s a p.i.t.a. to stretch onto nozzles, and then your old fuel line clamps won’t work as the O.D. is too small. It is pretty flexible stuff, stronger than stock it seems and it’s nice that you can visually see fuel in the system and moving for diagnosing / reassurance. It would be good for pump to carbs, fuel filter to pump, and probably pump to fuel tap / petcock runs. The short main and reserve to petcock / fuel tap runs have some pretty tight turns in them. So far I have left them and might order stock lines there.
BMW E28 era cars also use the same hose. You could get some 8mm from a BMW dealer.
Posted in DIY, repair and tagged aftermarket, diameter, Fuel hose, Fuel line, Kawasaki, kind, Ninja, replacement, size, sizing., type, Zx6e, zzr, zzr600 by green