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ordered a new gasket to see if thats the problem. im thinking when i tighten the bolts the cover presses on the idler gear causing it from moving. there is no evidence of rubbing anywhere in the flywheele or stator. will keep you posted

Just now took the stator and cover off the bike again and it started to crank. Now to see what’s going on. I put the cover with stator in without unbolting the cover to the engine and it cranks BUT as soon as i tighten a few bolts to seal it it stops cranking

the stator is bolted to the cover, i haven't removed it. It's just wired that with the stator and cover removed from the bike it cranks and starts.

I also have another good running 2007 FZ6, so I can swap parts between the two for testing. One thing I noticed, with the stator cover off it spins freely and even cranks and starts. That makes me think something is binding (possibly stator or cover alignment) rather than just a battery issue...

What I’ve done so far: Installed a new battery Replaced starter motor with a known good one Installed a new starter solenoid Verified wiring and connections Testing / timeline: Drained oil Removed left side cover and stator With cover OFF and stator removed bike cranked normally and even...

Starter motor is good and spins strong on bench. Engine rotates freely by hand. Tried jumping with a car battery and still same issue. With the idler gear removed, the starter spins fine when bypassing the solenoid. When the idler gear is installed, the system locks up, the starter won’t...

Just wanted to update for anyone chasing the same issue: My dash was stuck flashing EP almost all the time. The bike ran fine, but I couldn’t get into diagnostic mode and only once in a while the cluster would boot normally. What I did: Opened up the instrument cluster. Found signs of...

Thanks for the tips. I went through the battery, charging system, fuses, power, and grounds like you guys suggested, and that really helped me narrow things down. Here’s what I found step by step: Battery: 12.8–12.9 V key-off, holds strong under load. Charging system: New stator & RR, charges...

Hey everyone, I’ve got a 2006 FZ6 and I’m running into a weird electrical problem. The bike starts and runs fine, but the dash just flashes “EP” nonstop. I can’t even get into diagnostic mode when it’s doing this. Once in a blue moon, the dash boots normally (tach, fuel, speed, etc. all show...