BillyTheWrench
New Member
Hello Folks,
I try to keep away from posting unless I think it either A) is a new problem (which is rare, I know) or B) provides value to the existing pool of information. I'll try to keep it to the facts so here's the story.
FZ6 w/ ~30k miles. Normally stored outdoors, but garaged this winter. Filled the tank and added fuel stabilizer in November. Kept the battery indoors all winter. Charged it up, reinstalled and fired right up no problems. Drove it ~5miles to its summer location sometime in late May. Upon the second attempt at riding, the bike was warming up and over the course of ~2mins it began to slowly drop in rpm until the engine stalled.
Here's what I've tested.
Crank position sensor = 292ohm
CPS should be 248-372ohm
IN SPEC
All fuses are functional
Cap should be 10k ohh
Cap1: 10.51k
Cap4: 9.95k
Cap3: 10.27k
Cap2: 10.49k
Note: probe resistance: 0.7ohm
IN SPEC
Primary1-4: 2.5ohm
Primary3-2: 2.5ohm
Primary should be 1.53-2.07ohm
IN SPEC
Secondary coil should be 12k-18kohm
Secondary1-4: 15.3k
Secondary3-2:15.38k
IN SPEC
Checking the continuity(pg375):
⁃ Main switch: continuous
⁃ Clutch: 1300-50ohm, could be replaced
⁃ Side stand: continuous, open when stand is down
⁃ Engine stop: run=0ohm, stop=784ohm
⁃ Start: continuous when pressed
⁃ Brake: 0ohm when pressed, 2ohm when released
⁃ Oil level: 400ohm to ground
⁃ Neutral switch: continuous in both conditions, ~1800ohm in gear and ~1400ohm in neutral
Intake air temp sensor:
Spec = 2200-2700ohm
Measured = 1700ohm
OUT OF SPEC
Throttle position sensor testing:
Pin 1&3 spec (red & blue)= 4000-5000
Measured = 2.49kohm
Pin 2&3 spec (yellow & black) = twist throttle and measure at min and max
⁃ min: near 0
⁃ Max: no more than 3.5-6.5kohm
⁃ Measured Min: .350kohm
⁃ Measured Max: 2.05kohm
OUT OF SPEC
All injectors should be 12ohms
⁃ all injectors test at 13ohms
note: probe resistance is 0.7ohm
IN SPEC
So that's somewhat good news to find SOMETHING broken. I replaced the throttle position sensor and intake air temp sensor. I thought the TPS could be the issue but definitely not the air temp. Neither of them changed the behavior of the running issue.
At this point I pulled the spark plugs out and grounded them to the exhaust manifold. Nice healthy sparks while cranking so no issues there.
I was still skeptical of an ECU failure because I pulled the harness connector off and it was bone dry in there. No signs of fried pins. That doesn't mean its not fried, but given that its still behaving normally I figured I'd try out the fueling system.
I splash a bit of fuel down the throttle bodies and voila, we have a bit of idling going on. Given that I can hear the pump priming the system I do not suspect it's unhealthy yet, but that doesn't mean its providing sufficient pressure. I hop into diagnostic mode and while holding the throttle bodies open I trigger the injectors two at a time. I can see fuel injecting down the intake in a pretty healthy spray on all 4 injectors. I say what the hell and pull the fuel rail off then resistance test the injectors all individually which you can see in the data above they are all within spec as well. Clean 'em up then reassemble.
So now I'm thinking alright alright maybe even with fuel stabilizer the fuel pressure regulator could have gotten jammed or something. I buy another fuel line, cut it, and splice in a pressure gauge using 5/16 fuel line from autozone and a couple pipe fittings. Dump some fuel down the intake and crank it away. I got 40psi priming the pump and a little above that for the 10 seconds it was running on the fuel in the throttle bodies. Then it proceeded to die and only crank afterwards.
From the looks of this trouble shooting, I have fuel and spark present. I understand this is a machine, not a prototype, and magic does not exist in machines. I really don't want to replace the ECU because I just don't think its behaving like the ECU is trashed.
Any thoughts on this one?
Thanks in advance for taking the time to read! Sorry if something like this has been posted already. I was scrounging this and the sportbikes forums and didn't find any similar threads.
I try to keep away from posting unless I think it either A) is a new problem (which is rare, I know) or B) provides value to the existing pool of information. I'll try to keep it to the facts so here's the story.
FZ6 w/ ~30k miles. Normally stored outdoors, but garaged this winter. Filled the tank and added fuel stabilizer in November. Kept the battery indoors all winter. Charged it up, reinstalled and fired right up no problems. Drove it ~5miles to its summer location sometime in late May. Upon the second attempt at riding, the bike was warming up and over the course of ~2mins it began to slowly drop in rpm until the engine stalled.
Here's what I've tested.
Crank position sensor = 292ohm
CPS should be 248-372ohm
IN SPEC
All fuses are functional
Cap should be 10k ohh
Cap1: 10.51k
Cap4: 9.95k
Cap3: 10.27k
Cap2: 10.49k
Note: probe resistance: 0.7ohm
IN SPEC
Primary1-4: 2.5ohm
Primary3-2: 2.5ohm
Primary should be 1.53-2.07ohm
IN SPEC
Secondary coil should be 12k-18kohm
Secondary1-4: 15.3k
Secondary3-2:15.38k
IN SPEC
Checking the continuity(pg375):
⁃ Main switch: continuous
⁃ Clutch: 1300-50ohm, could be replaced
⁃ Side stand: continuous, open when stand is down
⁃ Engine stop: run=0ohm, stop=784ohm
⁃ Start: continuous when pressed
⁃ Brake: 0ohm when pressed, 2ohm when released
⁃ Oil level: 400ohm to ground
⁃ Neutral switch: continuous in both conditions, ~1800ohm in gear and ~1400ohm in neutral
Intake air temp sensor:
Spec = 2200-2700ohm
Measured = 1700ohm
OUT OF SPEC
Throttle position sensor testing:
Pin 1&3 spec (red & blue)= 4000-5000
Measured = 2.49kohm
Pin 2&3 spec (yellow & black) = twist throttle and measure at min and max
⁃ min: near 0
⁃ Max: no more than 3.5-6.5kohm
⁃ Measured Min: .350kohm
⁃ Measured Max: 2.05kohm
OUT OF SPEC
All injectors should be 12ohms
⁃ all injectors test at 13ohms
note: probe resistance is 0.7ohm
IN SPEC
So that's somewhat good news to find SOMETHING broken. I replaced the throttle position sensor and intake air temp sensor. I thought the TPS could be the issue but definitely not the air temp. Neither of them changed the behavior of the running issue.
At this point I pulled the spark plugs out and grounded them to the exhaust manifold. Nice healthy sparks while cranking so no issues there.
I was still skeptical of an ECU failure because I pulled the harness connector off and it was bone dry in there. No signs of fried pins. That doesn't mean its not fried, but given that its still behaving normally I figured I'd try out the fueling system.
I splash a bit of fuel down the throttle bodies and voila, we have a bit of idling going on. Given that I can hear the pump priming the system I do not suspect it's unhealthy yet, but that doesn't mean its providing sufficient pressure. I hop into diagnostic mode and while holding the throttle bodies open I trigger the injectors two at a time. I can see fuel injecting down the intake in a pretty healthy spray on all 4 injectors. I say what the hell and pull the fuel rail off then resistance test the injectors all individually which you can see in the data above they are all within spec as well. Clean 'em up then reassemble.
So now I'm thinking alright alright maybe even with fuel stabilizer the fuel pressure regulator could have gotten jammed or something. I buy another fuel line, cut it, and splice in a pressure gauge using 5/16 fuel line from autozone and a couple pipe fittings. Dump some fuel down the intake and crank it away. I got 40psi priming the pump and a little above that for the 10 seconds it was running on the fuel in the throttle bodies. Then it proceeded to die and only crank afterwards.
From the looks of this trouble shooting, I have fuel and spark present. I understand this is a machine, not a prototype, and magic does not exist in machines. I really don't want to replace the ECU because I just don't think its behaving like the ECU is trashed.
Any thoughts on this one?
Thanks in advance for taking the time to read! Sorry if something like this has been posted already. I was scrounging this and the sportbikes forums and didn't find any similar threads.