Need help translating fault codes from diagnostics!

[4sure]

Hi guys,

I have read the numerous threads on here about fault codes and what they mean, but i'm still puzzled by my issue:

here's the background: to do BD43 dual light mod, i took the battery out, the airbox out, and added my home-made wiring. a day later, i was ready to wrap it up, replaced everything back....and both headlights would NOT come on, and the bike would not start. The bike would try to turn over, but never starts.

1. i can hear the relay work at the back of the bike
2. if i connect the battery directly to the fuel pump, the pump works
3. when the main switch is off, voltage is 12V. However, when i measure when trying to start, i only get 8V.
4. all fuses in the back are good.
5. i ran the diagnostics mode and i get the following:

diag 01:16
diag 03:96
diag 05:36
diag 06:36
diag 07:0
diag 08:0.6
diag 09:0.0
diag 20n
diag 21n
diag 30 thru 60:0
diag 61:12,19,30,46
diag 62:4
diag 70:0

I disconnected the battery for a few minutes and reconnected, and i get the same faults.
my question is really about the fauls for diag 61. i have read the service manual but it's still not clear...
1. is "46" the last fault the computer recorded and it's telling me that something's wrong with my charging system (my battery is too low)? the 8v i get may be the reason??
2. would it explain also why my lights are not coming on?
3. how do i know if these faults are current or were recorded in the past?
4. these faults all seem related to the ECU, should i replace it?

please help, thanks!

 

[Shamus McFeeley]

Anytime an electrical problem shows up like this after you've done something with the wiring, chances are you've caused the problem and don't realize it. I don't know what you mean by "home made wiring", but if neither of the headlights work, you have grounded something that should not be grounded. You need to undo everything you did, paying careful attention to what is connected where. You might have improperly installed a wire somewhere and not realized it. By taking your time, you might find the problem.Then put it back together and see if the bike works. If it works, then you definately caused the problem. Once you figure that out, you need to start your modification all over again, double checking your work as you go.

All of those fault codes are pointing to an electrical malfunction, and I doubt the ECU died by chance.

 

[4sure]

thanks for the feedback...what i meant by home-made wiring is the addition of a wire from the electrical connector under the battery box to the right headlight. Yamaha had already installed a socket for that wire to control the low beam on the right hand side, so I just added a pin for that socket to finish the loop.
I un-did the whole mod before to see what i could have done, but still not working. I guess i need to trace my steps back again...

 

[TownsendsFJR1300]

My 07 headlights don't come on until the bike is started/running..

If your voltage is dropping to 8 volts I suspect your battery is toast. Get it LOAD TESTED after fully charging it. Sounds like it has a dead short in it.. It won't start with 8 volts, period. A bad battery will cause all kinds of problems...

I'm assuming the terminals are tight....

BTW, that many diagnostic codes point in that direction. I did the BD43 mod on mine, I had no electrical problems afterwards...

 

[chaskell27]

+3 to Townsends

I don't believe my '06 headlights come on until the bike is running either. I also did the mod and had no adverse affects from it. It works great!!! Charge the battery and load test it to see where you are. Good luck and let us know how that works

 

[RJ2112]

I'm in agreement with everyone else..... the battery is discharged.

The headlights are relay controlled, and will not come on until the bike is running. When you switch off the key, they will also turn off..... but if you use the 'kill' switch, and leave the ignition on, the headlights will stay illuminated.

The lamps will drain the battery in about 15 minutes, if you leave them both on without the motor running. It probably won't start at that point, but will 'bump' start. Go a half hour or more, and all bets are off.

 

[Naykid]

Apology for the hijack...but do fault codes atomatically display...or do you have to go to diagnostics to see them?

 

[chaskell27]

for my '06 you have to go into diagnostics mode. I can't remember what buttons you have to push to get there but if you use the search function on the forum, I'm sure you'll learn more than you care to know about the subject!!!

 

[4sure]

ok guys,
i changed the battery, i'm getting a good 12v under load now, but it's still not starting. However, the engine sounds different when i try to start, almost sounds like it really wants to start, but is out of gas???? can't really describe the sound...

i've checked the fuel pump before and directly connected to the battery, it spews out fuel...so i disconnected the power connector, and when i try to start the engine, i'm measuring the voltage at the connector. I'm not getting anything!!! i bet that's the problem!

i already checked the cutoff relay in the back per the service manual, and it had good continuity.

where are the power connector wires coming from? the cutoff relay?

 

[TownsendsFJR1300]

As I re-call not too long ago another FZ owner had a problem with corrosion in the relay for the fuel pump which was under the left side pod. It also had low voltage to the pump. Its a sealed unit, but he pried it apart and found all kinds of water corrosion in there.

Do a search on the subject, it wasn't that long ago, with in a month or so..

 

[4sure]

problem fixed!!!

with one more try in mind, i looked at the relay one last time and tested the continuity. i was tempted to open up the relay itself, but it seemed like it would be quite a job to pry it open...so i thought maybe i'll take a look at the fuses again....and lo and behold, the fuse for the EFI was blown!!!! all that troubleshooting because of a damn fuse arrrggghhh!!!
i swear i looked at all of them before and they were ok, maybe the fuse blew during all the troubleshooting that ensued after the initial check.

well at least my bike got a new fuel pump (not the $500 one, the $50 one from an R6), and a new battery, and i learned a lot more about the insides of an FZ6 than i cared for! lol

thanks for all the feedback and the recommendations! i can't believe a fuse got me puzzled for over a week!

 

[TownsendsFJR1300]

Congrates!!!!

You probably needed a new battery anyway if you had 8 volts in it.

As for the fuel pump, either save it as a spare or sell it on e-bay. They are sought after....