'03 zx12 mods

i have ordered a pair of heli-bars for my '03 zx12.
i notice the weighted hand tingles on slow trips.
a yoshi pipe, bmc filters and -1 tooth on front sprocket helped bring the power further down the rev range.
after reading about the torque restriction on the first 3 gears i joined the corresponding wires onto the 4th gear signal wire on the comp plug .this causes the more advanced 4th gear ignition map to be used when the bike is in any of the first 4 gears.
this makes the bike more responsive in the first 3 gears and especially at lower revs.the factory retarded the ignition map for safer response at low speeds. i only wish they did not increase the crank weight after 2000 but it sure is a nice ride now.
next i may add a 1 or 2 tooth larger rear sprocket for shorter wheel base and slightly lower gearing still.
as the speedo is driven by the gearbox i have installed a yellowbox to correct the speedo signal error.
a 190 rear helps turn in compared to the stock 200.

... after reading about the torque restriction on the first 3 gears i joined the corresponding wires onto the 4th gear signal wire on the comp plug .this causes the more advanced 4th gear ignition map to be used when the bike is in any of the first 4 gears.
this makes the bike more responsive in the first 3 gears ...

Welcome to KSRC

You have my attention ... you do this how? I have a power commander ... does this matter? Does this apply to later models as well?

You might also enjoy this forum ... http://www.ozzx12r.net/

Welcome to KSRC

You have my attention ... you do this how? I have a power commander ... does this matter? Does this apply to later models as well?

You might also enjoy this forum ... http://www.ozzx12r.net/

yep gidday and welcome too

I am curious too.....


ciao

Today i re-wired the small plug on the stock cdi under the glove box.
I was told the computer has retarded timing maps for the first 3 gears so the corresponding wires are soldered onto the 4th gear wire which has a normal timing map. This makes the bike mono easier in first and seems to have crisper response in first 3 gears.
The computer restricts the rev limit in top gear to just below 11 G, which is just under 300k with standard gearing.
To remove the speed limit the top gear wire is soldered onto 5th gear wire, letting the engine rev to normal limit in top gear.This may be helpful if you have reduced the standard gearing substantially.

Here are the instructions (thanks to Swede from ZX-12r.org)

Disable Speed Restriction
1 Pull out the CDI from it's rubber holder
2 Pull off plug marked 1425, the smaller plug.
3 on one side of the plug you will find a green/white wire and green/black wire.Free those wires to make room to work with them.Now cut the green/black wire about an inch from the plug.Isolate the wire coming from the plug.Un-isolate the green/white wire without cutting it. Solder the green/black wire to the green/white and isolate it.

Disable Torque Restriction
1 The green/red , green/blue , and green/yellow wires are to be cut an inch from the plug. (i staggered the 3 wire cuts to solder them along the exposed part of green wire)
2 Un-isolate the green wire about half an inch.You can use a lighter to warm the cable and pull the plastic back.
3 Solder the cables to the green cable.
4 Isolate and you're ready.

I found the wires located next to each other in rows on the plug.
Swede said he found this info on a german website and they had tested the mod on the autobahn.

i think it only applies for 02-03 bikes on. not sure about 04 on.
i could not buy an accessory hub for my yoshi ems to enable individual ignition maps for each gear so this evens the ignition maps before applying any further ignition timing mods across the board via the yoshi ems.

Very interesting info

I am thinking perhaps that this is why I was disappointed with the ZX12R... the one I rode was completely standard and barely got the front light on full gas in second!

I have a Power Commander... does this matter?

My understanding is that a Power Commander is an 'intercept' style ECU, which means that the ECU spits out a signal but the PC jumps in and changes it according to the tune. Depending on how the unit works it could well make a difference... if it works on percentages (eg. alter factory signal by 3%) then the factory restriction will affect the results... but if it gives out its own set of values (eg. ignore factory output and supply its own figure) then it would have no effect.

Gidday and welcome, I believe those instructions are not comapatible with 04-06 models but waiting confirmation of this as the later models had different wiring in some areas. Yep your mods are pretty much the standard thing to do, hmm I wonder if this a guy called Robby....

Today i re-wired the small plug on the stock cdi under the glove box.
...snip
i think it only applies for 02-03 bikes on. not sure about 04 on.
i could not buy an accessory hub for my yoshi ems to enable individual ignition maps for each gear so this evens the ignition maps before applying any further ignition timing mods across the board via the yoshi ems.

any idea if the mod applies to 2000-1 ZX1200A models

cheers

Havent heard this mentioned anywhere before ... thankyou kindly for the info ... might have to give this a try.

Pretty sure the power commander simply modifies the signal emitted by the ecu ... so to my mind shouldnt have any side affects to this mod.

... Yep your mods are pretty much the standard thing to do, hmm I wonder if this a guy called Robby....

Have you done this to your bike?

Today i re-wired the small plug on the stock cdi under the glove box.
...snip
i think it only applies for 02-03 bikes on. not sure about 04 on.
i could not buy an accessory hub for my yoshi ems to enable individual ignition maps for each gear so this evens the ignition maps before applying any further ignition timing mods across the board via the yoshi ems.

any idea if the mod applies to 2000-1 ZX1200A models

cheers

I belive the A models are unrestricted in speed but have the restriction on torque on first 3.

From what i have heard the Australian models may be similar to European bikes.
When i re-wired the small plug on my computer, the number on the plug was different and there were at least 2 extra wires of same colour but i found the 6 wires for the 6 gears in 2 rows next to each other.
If in doubt check with multimeter before cutting.
As Navpreet said(zx-12r.org), nearly 5 volts in neutral and 1.7 volts in the gear.
Make sure you solder the end of the wires from engine side of the cut to the uncut exposed wire, the plug side of the cut wire should be loose and taped over to insulate .
I have noticed a lighter colour on exhaust tip, presumably more fuel is being burnt in 3 lowest gears. Engine temp slightly higher at slow traffic speeds. Slightly better mileage around town also.
Next i want to remove some timing and/or fuel at low revs and wide throttle positions to fine tune with the yoshi ems.
A couple of times taking off quick at low revs in first the bike has coughed for a split second then taken off.

Havent heard this mentioned anywhere before ... thankyou kindly for the info ... might have to give this a try.

Pretty sure the power commander simply modifies the signal emitted by the ecu ... so to my mind shouldnt have any side affects to this mod.

... Yep your mods are pretty much the standard thing to do, hmm I wonder if this a guy called Robby....

Have you done this to your bike?

Budgetry restraints and will get there evenentually

fitted the heli-bars today and some foam gripcovers.
a nice improvement. no hand tingles yet and less of a reach forward.

fitted the heli-bars today and some foam gripcovers.
a nice improvement. no hand tingles yet and less of a reach forward.

mate


any pics?

power commanders only affect fuelling, not timing... so the timing retard eliminator shouldnt affect the state of tune

this is the left heli-bar


this is the foam grip cover. went for country ride today, the numb hand syndrome was almost non-existent, after couple hours slight tingling but much better than standard setup.