[bigred875]

I'm helping a friend swap out is blown motor from hiw 04 gsxr600 and putting in an 05 gsxr750 motor. This is one of those "direct swaps" you read about on the innerweb

Everything is pretty much done, when you turn the bike on it goes through all the "checks", the LCD screen doesn't spit out any errors or nuttin... When we try to start it the motor turns over but does not fire then eventually spits out the "FI" code on the LCD screen. There is a PCIII in the mix and for some reason my laptop does says it is not communicating with the PCIII but picks up the S/N of the unit and registers throttle position. It also picks up "something" when we tried starting it with it conencted but then returns to "not communicating"

It was getting late so other then a quick check of the connections we really didnt get into further..

possible problems:

-bad wiring connection - ground or a bad "clip" connection
-bad ECU - he bought this on ebay, 750 ECU needed for swap
-bad tip over or kickstand sensor - will the motor turn over if these are bad?

any tips from the "pros" would be greatly appriciated before we start troubleshooting.....thanks

[KillBill]

Red -

I know with the 06/07's the FI light comes on frequently and can be resolved by disabling the set valve -

hope this helps your buddy

fi light with set valve removal - Gixxer.com

[bigred875]

hhmmm....it doesnt start though...not sure if that is the same issue...and it is on the 04-05 models..

[Degsy]

Ground power commander to battery.

if no start, then try removing power commander from the loop.

derek

[bigred875]

checked that and going to disconnect the PC3 tonight i'll keep ya posted, thanks degs

[Degsy]

Sounds like it's definitely electronic in nature. There's not much reason why a fuse should have blown, so kinda put that to the back of your mind. Think about ECU (reseat the connection and check for bent pins).

How many times does the fi light flash? That's usually a code for what sensor is down.

derek

[Degsy]

Oops, forgot. The gixxas need to be in dealer mode to access the fi codes.

Talked to a contact of mine, he says set valve is the first thing to check.

Ryan, you're good with a soldering iron here's how you wire yourself a dealer mode switch and save the $60 diagnostic fee at the stealership.

degs

[bigred875]

it doesnt come on until i try starting it and it runs over several times....i think maybe 3-4 times?

[Degsy]

Originally Posted by bigred875

it doesnt come on until i try starting it and it runs over several times....i think maybe 3-4 times?

See post above and stick a DM switch on it, that's the way to START troubleshooting. Running blind without it.

[bigred875]

sweet...good info. thanks

[Degsy]

Originally Posted by bigred875

sweet...good info. thanks

Welcome, those instructions are for 03/04 bikes, but I have been told that the wiring didn't change for the 05s

degs

[TLRMan]

Originally Posted by Degsy

Welcome, those instructions are for 03/04 bikes, but I have been told that the wiring didn't change for the 05s

degs

and I just use a paper clip to jump the wires....

[Degsy]

Originally Posted by TLRMan

and I just use a paper clip to jump the wires....

This is a fuel injected bike, your powers are useless here Captain Carb!! muuhaaahahahahahaha!

[jamotech741]

the power commander issue is normal, on your year model it wont communicate until its running, if you toggle the kill switch from off to on with your cpu connected it will communicate while the fuel pump activates but will shut off when the pump stops. So you only problem is the no start, which is due to 600 and 750 ecu's being different. Get the 750 ecu and you should be good to go, remember the bike must be running on this model to upload your map. You are using the 600 ecu but the 750 motor correct?

bad ECU - he bought this on ebay, 750 ECU needed for swap

That means you dont have a 750 ecu or do you think you have a bad 750 ecu? Just want to be clear on your situation so my info will be accurate. If you already have the 750 ecu let me know we'll go from there.

[bigred875]

he purchased and installed the 750 ecu

[hessogood]

Is the fuel pump priming?

[jamotech741]

Ok, thats a bit more difficult. There is no good way to test an ecu other that swapping it to another 04/05 750. Buying used electrical parts is a crap shoot. Other things to check, the ground strap to the back of the motor is tight and good connection, all vacuum lines, especially the atmospheric pressure sensor. I assume youve already checked that all your connectors go to the right spots, more importantly coil and fuel injector connectores as they are interchangable. What about coils, those are different between the two models and will definately give you problems being there are resistance differences. All depending if the resistance is higher or lower you can do no damage or fry your ecu.

[jamotech741]

Dont worry about the kickstand switch, will cause engine to not turn over.

[bigred875]

Originally Posted by hessogood

Is the fuel pump priming?

it is turning on

[elwood206]

I had the same problem on my 954 with the pcIII, it would read serial # but that was it. it wasnt getting power, are you sure youre gettin 12v in the PCIII? The guys at dynojet were semmed to know their stuff when I called em, pretty helpful too.

[TLRMan]

Originally Posted by Degsy

This is a fuel injected bike, your powers are useless here Captain Carb!! muuhaaahahahahahaha!

Beg to differ

[jamotech741]

Originally Posted by bigred875

it is turning on

So you are using coils from a 750?
I also believe the power commander for the 600 and 750 are different.
Let me know if you checked the things I mentioned, inquiring minds want to know! Before you try to diagnose failures or mistakes made in any kind of motor swap you have to start with confirming what parts are the same and whats different between the two or youll end up hanging yourself.

[Punjistick]

Originally Posted by TLRMan

Beg to differ

Here's my dealer mode device.

[Kurlon]

The PC3 should have come with an adapter that'll let you plug a 9v battery direct into it. Don't ask why, but on many bikes they won't talk to your laptop with the bike on unless it's running or that battery is connected.

For now though, unplug the PC3, and eliminate that potential issue from the loop. Get the motor to fire on the stock ECU before you try and tune it.

Have you pulled a plug and verified you're getting spark?