cybex_
New Member
Greetings
I've recently finished with some electrical & cosmetic work on my bike (addition of lights) and fairing fixes, but when putting everything back together the bike won't start.
Video ref:
I went over key components and diag mode with some light multimeter usage. I can do more if required.
I'm using a 2004ss workshop manual for all references to procedures and checks.
Workshop Manual: FZ6-S(S), FZ6N - https://drive.google.com/file/d/1IvQmmtz071urPCFlDNn5d1M_dnrGKcW-/view?usp=sharing
Problem:
Bike is turning over/cranking (i.e. starter is turning the bike) but not starting (to idle).
Tried:
Diagnosis:
Sensor/button checks
NOT checked (since these are labour intensive, these are a very last resort)
Notes:
History:
Replaced sub wiring harness (blue/white connector) from kill switch, starter switch & brake light -> ECU coupler since it had intermittent connectivity, causing code 46 every now and then (i.e. this connector was the cause)
This blue/white connector previously resulted in the bike not starting, causing clicking sounds in the starter relay and prevented the bike not starting. For the time being, I directly soldered each connection together to eliminate a potential issue.
See images below as reference.
Sub-wiring harness connector
Sub-wiring harness location
Summary
It seems 2 of 3 components are present:
Any/all suggestions are welcome.
---
UPDATE 1:
Doing a few further diagnostic checks, I observe the following:
Notes:
UPDATE 2:
Battery started running low, cranked a few times.
Observed:
I'm still leaning towards an electrical issue of some kind, though I can rule out FI system.
I've recently finished with some electrical & cosmetic work on my bike (addition of lights) and fairing fixes, but when putting everything back together the bike won't start.
Video ref:
I'm using a 2004ss workshop manual for all references to procedures and checks.
Workshop Manual: FZ6-S(S), FZ6N - https://drive.google.com/file/d/1IvQmmtz071urPCFlDNn5d1M_dnrGKcW-/view?usp=sharing
Problem:
Bike is turning over/cranking (i.e. starter is turning the bike) but not starting (to idle).
Tried:
- Hold throttle open 100% while cranking several times in a row for a few seconds doesn't help either.
- Putting a few drops of petrol into the cylinders (above airbox), bike doesn't start either (possibly needs to be a mist?)
- Bump start (to 10-11km/h)
Diagnosis:
- Suspected electrical fault (related to fuel)
- Battery (2mo old) gives >13V under no load, ~9V when cranking
- Using car battery (car off) w/ jumper leads, bike cranks faster but not starting.
- Fuel pump primes (when kill switch is off and/or when checking in diag mode, )
- when removing fuel host from pump to injectors, some (~20-30ml) pressurised fuel comes out after each prime cycle
- Fuel tank has no vacuum (audible sound when opening tank) upon fuel pump prime
- Fuel injection system voltage: 12V (diag Code: 09)
- Fuel injection system relay functional (audible check, diag code: 50)
- Solenoid functioning (audible check, diag Code 48)
- All fuses checked (EFI, Ignition, main, etc).
- No engine warning light,
- No error codes in cluster (normal)
- (after bike power cycle i.e. w/ current starting issue), no stored error codes in ECU memory
Sensor/button checks
- Kill switch has continuity
- Neutral (diag code: 21), sidestand (diag code: 20) sensors checked (diag mode)
- Crankshaft position sensor checked (normal, 200 ohms)
- Tilt sensor reading within required limits (diag code 08)
- Starter cut-off relay checked (manual, 8-12: Ignition System (13) AND diag mode, audible clicking sound)
NOT checked (since these are labour intensive, these are a very last resort)
- Spark plugs
- Secondary coil resistance
- Fuel injectors
- Compression (don't have necessary tools atm)
Notes:
- When unplugging crankshaft position sensor, I'd expect to see an error code 12 (even after power cycle) on cluster (normal/diag mode), this does not show.
Fault Code 12: No normal signals are received from the crankshaft position sensor.
- Unplugging the kickstand sensor does not show any error code.
- Unplugging intake temperature sensor shows error 22, this is the only sensor of the 3 mentioned that affects the cluster.
Fault Code 22: Intake temperature sensor-open or short circuit detected.
History:
Replaced sub wiring harness (blue/white connector) from kill switch, starter switch & brake light -> ECU coupler since it had intermittent connectivity, causing code 46 every now and then (i.e. this connector was the cause)
Code 46: Power supply to the FI system is not normal.
This blue/white connector previously resulted in the bike not starting, causing clicking sounds in the starter relay and prevented the bike not starting. For the time being, I directly soldered each connection together to eliminate a potential issue.
See images below as reference.
Sub-wiring harness connector
Sub-wiring harness location
Summary
It seems 2 of 3 components are present:
- Compression
- Spark
- (missing) fuel
Any/all suggestions are welcome.
---
UPDATE 1:
Doing a few further diagnostic checks, I observe the following:
- In diag mode, testing injectors (code 36 & 37), I can clearly see a light mist sprayed into the cylinders.
- Some sensors aren't being detected as disconnected.
- Disconnected main switch, immobiliser connector (from keyhole on lhs to ECU / main harness)
- disconnected crankshaft position sensor (expected to see fault code 12, was never detected)
- disconnected ECU plug (after ~8s on normal cluster, Er_1 was visible - normal)
Notes:
- After reconnecting ECU plug (while, crankshaft & intake air temperature sensors were disconnected and main switch/immobilser lead was disconnected), I mistakenly attempted to start. Bike cranked but didn't start. Code 22 was visible on cluster.
- Reconnecting air temperature sensor (w/ crankshaft sensor and main switch/immobilser lead was disconnected) bike cranked, no start. No error codes visible (in normal/diag mode).
- Continuity test between crankshaft connector -> ECU shows connection.
- NOTE: According to manual, I should not be able to start (crank?) w/ faulty/disconnected Crankshaft position sensor
UPDATE 2:
Battery started running low, cranked a few times.
Observed:
- Battery w/ no load: ~12.5V
- Battery while cranking: ~8.7V drops to ~6V then stops cranking
- During this 'low power' crank, no engine warning light (all previous cranks mentioned in O.P. above had it on while cranking).
- While cranking (with low power), Er_1 displayed on cluster for cranking duration only (first time seeing this).
I'm still leaning towards an electrical issue of some kind, though I can rule out FI system.
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