Dies after putting into gear

pulsar2

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My bike has this strange problem that started yesterday without warning - engine stops if I put it in gear. I initially thought it was the side stand switch, but no use even after shorting the two wires. Pulling the clutch in, I hear one of the relays click randomly, like sometimes it does, sometimes it does not. I am able to crank the engine when I hear the click while in gear, but the engine does not fire. In neutral, it fires just fine till I put it in gear and the engine cuts off. I suspect the battery is toast as it doesn't seem to have any power left after a couple of short cranks - even after fully charging it overnight.
No error codes on the display, cycled through diag mode but not sure what I need to be looking at for this problem. :(
 

elus1ve

Member
Other more knowledgeable ppl can help you better but just a question on the side stand switch - isn't it the other way around? Shorting it means it will cut off the engine in gear, while open circuit means it will allow the engine to run?
 

pulsar2

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Other more knowledgeable ppl can help you better but just a question on the side stand switch - isn't it the other way around? Shorting it means it will cut off the engine in gear, while open circuit means it will allow the engine to run?
Tried both actually, removing the connector for the switch - basically open circuit did not work. I also disassembled the switch to check and it is actually closed when the side stand is up.

Problem should be clutch switch.

Too many switches, too many problems :confused:
Maybe.. there is some weight behind doubting the clutch switch - as I think the engine cutoff as soon as I pulled in the clutch to downshift to first while entering the fuel station. Didn't think of it much at that time, will give it a proper cleaning in the evening.
 
Underneath the left side panel(by the seat) there are relays and a connector next to each other. On my bike the connector came loose and caused the same issue as you're experiencing when putting my bike into gear. I plugged it back in and it fixed it.
 
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Motogiro

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The safety cutout/starter interrupt unit requires logic from the ECU and 3 switches. The clutch, side stand and neutral safety switches. If the side stand is down (open state) and the neutral safety switch is (open state) in gear, the engine will shut off. The clutch switch is only for starting and sometimes timing on some bikes so I don't think the clutch switch is in question for the engine stopping. Check your neutral safety switch and wiring. :)
 

pulsar2

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Underneath the left side panel(by the seat) there are relays and a connector next to each other. On my bike the connector came loose and caused the same issue as you're experiencing when putting my bike into gear. I plugged it back in and it fixed it.
I did try that after I read through your thread, but it did not help.

The clutch switch is only for starting and sometimes timing on some bikes so I don't think the clutch switch is in question for the engine stopping.
That is my thought too, but like I mentioned - pulling the clutch in doesn't seem to activate the relay all the times - I am able to crank the engine only sometimes while in gear and other times I dont hear the relay click at all.

Check your neutral safety switch and wiring. :)
About the neutral switch - where is it physically located? Anything I can test to make sure the switch works good? I see the neutral light come and go as I shift the gears.Also, the bike runs fine when started in neutral. It dies only when shift to any gear or doesnot fire up when I try to start in gear with the clutch pulled in - just keeps cranking.
 

Motogiro

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I did try that after I read through your thread, but it did not help.



That is my thought too, but like I mentioned - pulling the clutch in doesn't seem to activate the relay all the times - I am able to crank the engine only sometimes while in gear and other times I dont hear the relay click at all.



About the neutral switch - where is it physically located? Anything I can test to make sure the switch works good? I see the neutral light come and go as I shift the gears.Also, the bike runs fine when started in neutral. It dies only when shift to any gear or doesnot fire up when I try to start in gear with the clutch pulled in - just keeps cranking.
This sounds like you may be having a failure of the safety cutoff/starter interrupt unit. It has 2 relays in it. One relay is the starter interrupt and the other relay runs the fuel pump. Other circuits that will tell the ECU there's a problem is the Lean Angle Switch, Throttle Position Sensor, and Intake Air Pressure Sensor but you would see an error code from the latter 2 sensors. I don't know about the lean angle sensor. The ECU will not activate the fuel pump relay coil if it sees a problem and I think we would see an error code. Check the pins on the plug on your safety cutout assembly. There are, IIRC, 13 wires on a 16 pin plug. The other unit in that pod is the headlamp relay assembly. Call me later. :)
 

pulsar2

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This sounds like you may be having a failure of the safety cutoff/starter interrupt unit. It has 2 relays in it. One relay is the starter interrupt and the other relay runs the fuel pump. .........Check the pins on the plug on your safety cutout assembly. There are, IIRC, 13 wires on a 16 pin plug. The other unit in that pod is the headlamp relay assembly. Call me later. :)
That was it :thumbup: , a test on each pin on the Starting circuit cutoff relay showed that the diode that completes the path of Clutch Switch and the Sidestand switch was malfunctioning. I checked the current flow in that path and found only about 70mA, so added a general purpose diode - 1N4148(use a different one?) between the line from clutch switch and the side stand switch. Now the bike starts and runs just fine in gear. Not sure what caused the diode to blow in the first place, so I am now carrying a couple of bits of wires to add a jumper if the spare diode I placed fries too Blah.
 
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Motogiro

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That was it [emoji106] , a test on each pin on the Starting circuit cutoff relay showed that the diode that completes the path of Clutch Switch and the Sidestand switch was malfunctioning. I checked the current flow in that path and found only about 70mA, so added a general purpose diode - 1N4148(use a different one?) between the line from clutch switch and the side stand switch. Now the bike starts and runs just fine in gear. Not sure what caused the diode to blow in the first place, so I am now carrying a couple of bits of wires to add a jumper if the spare diode I placed fries too Blah.
Great job! I've been wanting someone to send me a broken one so that I could possibly repair them. There is a zener diode that I'd like to know the value/or part number of. If I had a broken unit I could see if it's serviceable. Two of the diodes are spike protection at the relay coils.
 
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pulsar2

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Looking at the connections, it looks like it is spike protection for the starter relay but strangely tied to the battery positive terminal. Expecting a higher(>12v) voltage spike from the starter relay maybe? I will try to measure it later today and let you know, although I can measure it only if is within 12v though.
 

elbeard1989

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first time reacting to posts since i cannot create a thread i am experiencing an issue with my 07 fz6 just bought two months ago was ridding fine for about two weeks went out one day to start it and let warm up. put into gear and bike dies. according to my diag. my neutral safety switch is good and so is my kickstand switch i think. tried jumping the clutch switch to see if that was the problem but same results every time i put the bike into gear it dies will not allow me to start bike in gear either its driving me crazy. first time bike owner but not first time working on
 

Motogiro

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first time reacting to posts since i cannot create a thread i am experiencing an issue with my 07 fz6 just bought two months ago was ridding fine for about two weeks went out one day to start it and let warm up. put into gear and bike dies. according to my diag. my neutral safety switch is good and so is my kickstand switch i think. tried jumping the clutch switch to see if that was the problem but same results every time i put the bike into gear it dies will not allow me to start bike in gear either its driving me crazy. first time bike owner but not first time working on
:welcome: to our great family!
If you see your neutral safety light on your instrument cluster then you may have a problem with the fore mentioned module in this thread. Check your harness from the ignition switch assembly to insure the harness has not been tampered with. This is a common failure with attempted thefts. I would also prop up the tank and carefully inspect your wiring harness. Pull the side pods and inspect wiring. Rodents are known to get into wiring and gnaw through wires. Once this is done we can go over continuity tests at the module plug to rule out an open circuit.
 

elbeard1989

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thank you i will try to look at that tonight its just weird that i rode it one day then the next day it just dies when putting into gear. i bought this bike used with no original tools or manuals so i printed one out ended up being 500+ pages i will have to go through them and look to see where all these are located. Do you know if on the instrument cluster if you are in diag. mode that kickstand switch should be reading off when stand is up whether or not it is in neutral it seems like on mine it only turns off when i start to put it into gear.
 

Motogiro

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[MENTION=29728]elbeard1989[/MENTION] I will PM you...
 
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