2012 ER6f exhaust help needed

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

Hi, I've found myself with a problem and I can't work out what I've done wrong and I struggling to even describe the issue. I'll try.
I fitted an aftermarket can and downpipes from a 2008, this was fine, although it didn't sound very good. It wasn't just too loud, but the backfires didn't sound healthy at all. I took them off and installed a yoshi full system, this was fine for a week or so. Now it sounds really bad, it sounds like the bike is shitting rust through the exhaust. I thought it might be due to the PAIR valve, so I plugged this too and there is still no change. The backfires sound very loud, a bit tinny and almost a bit hollow. I worried at first that it didn't have enough oil, but the oil is fine.
It will start and idle, but it's like there is no exhaust on at all. The pipe and connectors all look fine, the exhause gas is coming out the end where it should. To top this off, it's overheating really quickly, for example after 5 mins in traffic, the warning light is coming on. If I turn the bike off, it sounds like a boiling kettle, and it's never dome that before. I can only assume that I've moved something, or broke something. My plan is to take it off and check it over, any other ideas??

Many thanks
Fatjames

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

Kawi forums are telling me I need to get a power commander as the fueling is fucked. Does that sound right?

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

jeddy11 · Traffic Copper Joined: 06 Jul 2012 Karma :

Sounds like a fuelling issue the FI should auto adjust for the new pipe what helped mine when i fitted an aftermarket exhaust as it was also running a bit rough was to block the pare valve and then pulling the fuse to the ecu and resetting so when it started up again im not if it reset the fuelling or what ever but it ran a whole lot smoother and used less fuel to boot i then wondered why i hadnt tried this earlier.. Thumbs Up

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fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

I've plagued the PAIR valve already. Just had a look and the fan is not coming on, even with the engine hot light on, on the dash. I'm
Tempted to put the old pipe back on and see if the problem goes. Fuck knows what happened to the fan!

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

More good news! The leisure battery I run my garage lights from is dying. I'll have drag it home and charge it before I do anything else. Evil or Very Mad

Aff · World Chat Champion Joined: 05 May 2011 Karma :

Check the fan first before you start assuming its all exhaust.

Have you made sure nothing is unplugged?

If so, is the fuse good?

If it is, run power to the fan directly from you battery, ground it wherever convenient. If it doesn't come on, your fan is dead. If it does then the control system is dead somewhere.

I believe the er6 only has the one CTS so if that goes it will also effect the fan, this would also have bad effects on the running and sound of the bike, as the ECU uses this to find out if the bike should be on its warm up cycle or not, this will be injecting much more fuel into the engine.
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fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

Aff · World Chat Champion Joined: 05 May 2011 Karma :

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

I just went back to the garage to get the battery and had a look. I need more light to be sure, but it looks like the wire for the fan goes under the tank. More light tomorrow and I can look properly.

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

I think I fucked my battery. It was on charge all night and nothing! These repairs might have to wait until the weekend Sad

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

The good: I charged up my garage battery and have light.
The bad: the fan is what's broken. I've ran 12v through it and nothing. Looking online, a new one is £240!!! I've already drained the coolant, so may as well take the fan off and see if it's serviceable. Any ideas, please let me know.
FJ

Aff · World Chat Champion Joined: 05 May 2011 Karma :

That Fan is used on all 2006 - 2012 er6f's and n's. Its also used on all 2006-2012 Versys.

You should be able to get it at a reasonable price off a bike being broken.

Alternatively, buy a dirt cheap fan of similar size off another bike and bodge it on, wont be hard.

Also I'm sure i've seen a pattern part for it somewhere.

:edit: just as a note, when i say used on all of them, the 2006-2009 used the exact same shape fan but with 4 mounting points, the later ones used the same fan, but with one of the mounting legs cut off, so the old fan fits but you have to either remove or not fit one of the mounting legs.

Like so:

https://i.imgur.com/7YTd2AV.png
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fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

Found one on eBay for £27 and ordered it. Do you think it's a coincidence that this has happened? The fan is behind the rad, so I didn't go near it when I installed the exhaust. It was really dirty, might need a fender extender too.

Aff · World Chat Champion Joined: 05 May 2011 Karma :

They really don't take much to burn the motor out, Its definitely worth taking it apart to look for any obvious problems.
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fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

Aff · World Chat Champion Joined: 05 May 2011 Karma :

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

I tested the new fan before putting it. Refilled the coolant and let it hear up. The temp warning light has come on and the fan hasn't. Wtf?? Maybe the fuse. I'll check that.

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

The fuse had blown. Phew. For anyone with a 2012/2013, the fuse box is under the plastic at the front of the tank. To the left of the ignition key hole!

Matt B · World Chat Champion Joined: 01 May 2012 Karma :

fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

The fan was still fucked, so not much in it. Finding the fuse box was a bastard though!

Aff · World Chat Champion Joined: 05 May 2011 Karma :

Clutchy · World Chat Champion Joined: 08 Nov 2011 Karma :

If the exhaust is still sounding bad, my friend had this exact problem on his er-6f, the exhaust wasn't sealing properly and had to use gun gum as a bodge! I know you said you checked it all, but have another look where the base of the end can is connected. Thumbs Up

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fatjames · World Chat Champion Joined: 09 Jul 2011 Karma :

I think you're right mate. It's got that hollow plinking sort of sound, there is either air getting in, or it's too lean. Even with the PAIR valve plugged there is a lot of back firing, not that I mind unless its causing damage. I'll take it for a test ride and see how it behaves. Ideally, I want to avoid having to get a pc and dyno because I'm too poor!