|
Author |
Message |
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
Posted: 15:57 - 16 Aug 2020 Post subject: ZX6R electrical nightmare |
|
|
Hi all. I'm hoping someone can make a suggestion as to what the hell is going on with my 2006 ZX6R as there seem to be electrical issues everywhere. It hasn't been out much over the past year (other than back and forth in the garage), mainly due to work at the house blocking the path out. However it felt fine when I did eventually get it out again. At this point I started noticing electrical issues and I'm losing the will to live trying to trace the fault(s).
First, I started having to hold the start button for about 10 seconds or it would cut out as soon as I let go. This has been happening the past couple of months
Over the past couple of weeks, it intermittently wouldn't start (including right after MOT even though it started fine 3 times already that day, then eventually started after I pushed it to the top of a hill (my parents live nearby so I was pushing it to their house). It doesn't even try to crank, and only sometimes can you hear the fuel pump priming. Now it just won't start at all, except from a bump start (once it's going it runs fine).
When it's running and you put the sidestand down it cuts out, then won't start again. This was happening for the past few weeks. I've replaced the sidestand switch but it has made no difference. Did a continuity check on the clutch switch and it was okay. Connector was getting 2 volts (is this about right?)
It's only thrown a code once recently while I've been riding it (camshaft position sensor malfunction, wiring open or short). When I went into Dealer mode 2 to read all stored codes I got 6 in total, though I don't know how long any/all of them have been there
13 - Intake air temperature sensor malfunction, wiring open or short
23 - Camshaft position sensor malfunction, wiring open or short
32 - Subthrottle sensor malfunction, wiring open or short
34 - Exhaust butterfly valve actuator sensor malfunction, wiring open or short (it has a bypass on it due to previous issues so this might be historic)
35 - Immobiliser amplifier malfunction
64 - Exhaust butterfly valve actuator malfunction, wiring open or short (see code 34)
I cleared all the codes, and have been out on the bike since then (bump start) and no codes came up. Granted it was only a 10 minute or so ride.
Can anyone suggest where I might begin to try to sort this out? ____________________ Current bike - 2006 ZX6R |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Tankie |
This post is not being displayed .
|
Tankie Crazy Courier
Joined: 24 Feb 2017 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
stinkwheel |
This post is not being displayed .
|
stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Robby |
This post is not being displayed .
|
Robby Dirty Old Man
Joined: 16 May 2002 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nobby the Bastard |
This post is not being displayed .
|
Nobby the Bastard Harley Gaydar
Joined: 16 Aug 2013 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
stevo123 |
This post is not being displayed .
|
stevo123 Nitrous Nuisance
Joined: 10 Aug 2004 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
pepperami |
This post is not being displayed .
|
pepperami Super Spammer
Joined: 17 Jan 2010 Karma :
|
Posted: 09:05 - 18 Aug 2020 Post subject: |
|
|
When was the last time you put fresh fuel in it?
Seriously, mine sat for a year , when I used it, it cut out once or twice, and was a hard starter.
A tank of fresh fuel and a good long run appeared to solve the problem. ____________________ I am the sum total of my own existence, what went before makes me who I am now! |
|
Back to top |
|
You must be logged in to rate posts |
|
|
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
Posted: 10:36 - 23 Aug 2020 Post subject: |
|
|
Well, that didn't go as planned.
On Thursday, I took the tail cowling off to have a look at relays etc, but then got called away. On Saturday morning, I went out, turned the key in ignition and heard the fuel pump priming. I pressed the starter button and it fired up instantly. Didn't have to hold the starter button like I've had to do recently. After letting it run for a while, I put it back together enough take it for a ride, then tried to start it again. Still no issues. Took it out for a test ride along the bypass and back, put the sidestand down expecting it to cut out, but no, still running as well as it has ever done.
So now I'm torn between accepting this miraculous recovery and taking the bike out every chance I get, and thinking it would probably be sensible to take it apart again to try to find the initial cause of the problem to make sure it doesn't happen again and leave me stranded (though at least I know bump starting it works and I have breakdown cover if I get really desperate).
Anyway, thanks everyone for your advice ____________________ Current bike - 2006 ZX6R |
|
Back to top |
|
You must be logged in to rate posts |
|
|
davebike |
This post is not being displayed .
|
davebike World Chat Champion
Joined: 15 Nov 2013 Karma :
|
Posted: 09:48 - 24 Aug 2020 Post subject: |
|
|
Battery probibly get it and the charging system tested !
Low/poorly battery can cause all sorts of issues and all sorts of fault codes ! ____________________ Dave
NC750Xdct + others at work !
davebike1@gmail.com |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Old Thread Alert!
There is a gap of 236 days between these two posts... |
|
|
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
Posted: 14:48 - 17 Apr 2021 Post subject: |
|
|
Sorry to resurrect a thread from nearly a year ago, but this bike has nearly destroyed my sanity after the electrical gremlins stopped self-isolating. Thankfully, I think I've finally found a workaround for the issue, if not necessarily "fixed" it.
All was going well so I fitted a new chain and sprockets a few weeks ago, and changed oil, filters and spark plugs. Bike was running well until I put the fairings back on, then it wouldn't start. I took them off again, and it still wouldn't start (not that I expected that to make a difference), though on one attempt the fuel pump primed after a delay and then the bike started fine. I tried refitting the fairings while it was running and, when moving the wiring loom, it cut out and wouldn't start again.
After a lot of faffing about checking wires, connectors, etc, I discovered that the fuel pump connector wasn't getting voltage when turning the key. After more faffing about, I tested it again when the sidestand just happened to be up and this time it got voltage, but it still wouldn't start/crank, except when the clutch was pulled in. It then cut out as soon as side stand was put down. I used the connector from my old sidestand switch as a bypass and now the bike starts every time as long as the clutch is pulled in. I've never in my life tried to ride off with the stand down, so I'm relatively happy with this workaround.
This is where I'm still confused though. Not sure if I have a dodgy neutral switch (continuity was fine on both sidestand switches I had), but the neutral light comes on and goes off exactly as it should. Just wanted to post an update to see if any of the BCF experts could shed any light on any other possibilities I might be missing.
Edit: I should add, the same fault codes came up again just after I serviced it and it wouldn't start. However, they're no longer coming up... ____________________ Current bike - 2006 ZX6R |
|
Back to top |
|
You must be logged in to rate posts |
|
|
bikenut |
This post is not being displayed .
|
bikenut World Chat Champion
Joined: 21 Nov 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
jeffyjeff |
This post is not being displayed .
|
jeffyjeff World Chat Champion
Joined: 02 May 2020 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
bikenut |
This post is not being displayed .
|
bikenut World Chat Champion
Joined: 21 Nov 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
jeffyjeff |
This post is not being displayed .
|
jeffyjeff World Chat Champion
Joined: 02 May 2020 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
bikenut |
This post is not being displayed .
|
bikenut World Chat Champion
Joined: 21 Nov 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nutty |
This post is not being displayed .
|
Nutty Two Stroke Sniffer
Joined: 16 Jan 2021 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
aaronb74 |
This post is not being displayed .
|
aaronb74 Crazy Courier
Joined: 05 Aug 2008 Karma :
|
Posted: 20:29 - 20 Apr 2021 Post subject: |
|
|
Thanks for all the comments and suggestions. I do have a wiring diagram and will print out the diagram above. I understand the basics of electrical fault finding, but wouldn't consider myself an expert by any means (and more knowledgeable people aren't allowed to visit my house, lol), so apologies in advance if I say stupid things .
I had a good look at most - though admittedly not all - of the loom, particularly around the cluster of connectors at the front, where the problem seemed to originate, and going back to under the seat (though it got more difficult from there with all the engine sensor wires being wrapped separately and feeding into it). For the most part, the wiring looked to be in good condition, as did the connectors. No parts of the loom were strained, but it looks to have been routed incorrectly at some point, presumably when it was in the garage for an electrical issue many years ago. Instead of following the cable tie points on the frame, it was hanging down slightly and went over the radiator (now restored to the correct place). There were a few bits of the loom where wires seemed to be spliced together/go off in different directions, but I couldn't tell if these were factory jobs or the previous owner's DIY work (the bike was 4 years old when I bought it and only modification was heated grips, but wiring for those is separate). These sections were reasonably well insulated, though I was surprised at just how much bare ware there was under the insulation. I can't recall off the top of my head which wires they were (one may have been connected to the kill switch...).
The only connector that was a bit iffy was (unless I misread the wiring diagram) the lap timer. All others appeared clean and wires looked good
The only earth point I could see on the loom was onto the top of the engine, which looked absolutely fine...
I'll try to have another look this weekend and update you on my findings. ____________________ Current bike - 2006 ZX6R |
|
Back to top |
|
You must be logged in to rate posts |
|
|
bikenut |
This post is not being displayed .
|
bikenut World Chat Champion
Joined: 21 Nov 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Old Thread Alert!
The last post was made 3 years, 3 days ago. Instead of replying here, would creating a new thread be more useful? |
|
|
|