After picking up my 2003 ZX6RR last month, I noticed some funky stuff happening during rides. Since I’m cheap and stubborn, I decided to tackle these gremlins myself instead of paying shop rates. Grabbed my toolbox and dove headfirst into the mess.
Problem #1: Choke Acting Weird
Bike wouldn’t idle when cold – just died like it was mad at me. Popped the fuel tank off with a 10mm socket:
- Tore apart the choke plungers – nasty black gunk everywhere
- Scrubbed ’em with carb cleaner till they shone like new dimes
- Lubed the cables with WD-40 till they moved smooth
Fired her up next morning – purred like a kitten without dying. Total time? Maybe 90 minutes including beer breaks.
Problem #2: Regulator Cookin’ Itself
Battery kept dying mid-ride. Tested voltage with a $5 multimeter from Harbor Freight. Revved the engine and saw over 16 volts – yeah, that’ll fry things.
- Unbolted the fried regulator behind the fairing (three bolts)
- Swapped in a cheap aftermarket unit – no fancy OEM crap
- Slapped dielectric grease on the connectors to prevent corrosion
Now voltage stays steady around 14 volts while riding. Saved $300 on shop labor doing this in my driveway.
Problem #3: Chain Slappin’ Like Crazy
This annoying CLACK-CLACK sound came from the rear when shifting. Turned out the chain was looser than my college jeans.
- Put bike on rear stand – used scrap wood blocks when the stand didn’t fit perfect
- Measured slack with a ruler – like 3 fingers worth, way too much
- Adjusted those crusty adjuster bolts with PB Blaster and elbow grease
Made sure both sides were even by counting bolt threads. Took it around the block – silence! Felt like a genius for two seconds till I spilled chain lube on my shoes.
Point is, this old bike ain’t perfect but with basic tools and YouTube tutorials, you can fix most stuff yourself. Just bring patience and Band-Aids for the busted knuckles.
