600rr Cutting Out

[Catach]

I was at NJMP on Tuesday and managed to mess something up, but I dont know what exactly. I was coming over the hill before T5 and as I crested the hill I went to shift from 2nd-3rd and missed, slammed the rev-limiter and the bike died.

Symptoms: The bike runs, sort of. Sometimes when I turn the key on the relay closest to the front of the bike on the left side clicks and the fuel prime does not prime. Sometimes the clicking stops and the pump primes, sometimes it primes right away when I turn the key. Obviously the bike will not start unless the pump primes. When the bike starts it idles perfect but the temp gauge goes all over the place, the gas gauges does as well. Sometimes when I turn the key none of the gauges light up unless the kill switch is OFF. Sometimes the FI light comes on and stays on but only after I rev the bike and it dies. I can give the bike a little gas but if I get over about 6k it sounds as if it is hitting the limiter and then cuts out. There are no abnormal mechanical noises and I have not yet been able to get at the bike with a multimeter.

Things I have already tried:
-Unhooking the battery for 1hr-ish
-Touching uncharged battery cables together to discharge everything
-Unhooking ECU
-Tapping TPS sensor
-Check fuses
-Swap clicking relay

Anyone seen anything like this before? I wont be able to work on the bike at all until Saturday morning so I want to spend this week coming up with idea of what could possibly be wrong with it. Thanks in advance for any help!

[Nate Dawg]

any chance its still wet from Mon. Maybe there is some water in a coupler or connection somewhere

[butcher bergs]

Touching which cables together to discharge what?

Whatever it is, I'd like to suggest you don't do that anymore.

[Catach]

edited

[Catach]

any chance its still wet from Mon. Maybe there is some water in a coupler or connection somewhere

checked just about every connection I could get to and it didnt happen until about 130pm so the bike had been hot and I assume was totally dry by that point. I cant imagine hammering the rev limiter then this problem starting is a coincidence, but I have no idea what could have broken or why. revs shouldnt break electrical things

[akira700]

I had similar erratic behavior and I took it to Degsy.
Turned out that my wiring harness coupler near the
front left ram air duct had corroded due to alot
of winter riding with moisture and salt.

I'd un-couple those, clean them up with small file or
sand paper and then hit with some dielectric grease.
If that dont work take it to the Degs.

-Akira

[F4Iguy]

probably the worst thing ever with any kind of machinery are electrical gremlins. with all sorts of crazy shit happening, best i can think of is that it's shorted somewhere. i'm just guessing here, but my thought is that if it surged, you may have cooked some wires, (although problems like these rarely ever makes sence). check all your harnesses for burning, chafing, melted stuff, etc. i'm curious to know whats up. good luck man.

[Nate Dawg]

i had an electrical problem that i never diagnosed. Degs and I worked on it for 3 months.. If you can't figure it out buy a used wiring harness off ebay. I paid $75 for mine

[Degsy]

It's a bad ground with all those symptoms and it's almost certainly in the blue or orange connector in by the left ram air duct. That connector carries the grounds for many of the "A-OK" signals that the bike needs to prime the pump.

[Degsy]

i had an electrical problem that i never diagnosed. Degs and I worked on it for 3 months.. If you can't figure it out buy a used wiring harness off ebay. I paid $75 for mine

worst electrical bug I have ever seen, that one.

[butcher bergs]

Have a different ECU?

Thinking some water was already in the system somewhere and whichever circuit fires the rev-limiter is the root cause of what set everything off.

[F4Iguy]

It's a bad ground with all those symptoms and it's almost certainly in the blue or orange connector in by the left ram air duct. That connector carries the grounds for many of the "A-OK" signals that the bike needs to prime the pump.

so how do u fix something like that? replace the connectors? or the entire harness?

[Nate Dawg]

worst electrical bug I have ever seen, that one.

but you sure as hell weren't about to give up easily!!!! we pulled out just about every stop. you even had a 1+ hour conversation with a Suzuki tec.

[Degsy]

so how do u fix something like that? replace the connectors? or the entire harness?

Drive bike to degsy's house of pin extractors and files with a fistfull of cash.

LOL, remove pins from connector block, file or emery clean, electrical cleaner, dielectric grease the crap out of them and stuff it all back together.

[beet]

[F4Iguy]

Drive bike to degsy's house of pin extractors and files with a fistfull of cash.

LOL, remove pins from connector block, file or emery clean, electrical cleaner, dielectric grease the crap out of them and stuff it all back together.

uh, fair enough. damn.

[Degsy]

uh, fair enough. damn.

Yeah, it's an easy fix ONCE you know where the bad ground or short is. Reading the wiring diagram is the hard part. They are so hard to read on japanese bikes.

[F4Iguy]

Yeah, it's an easy fix ONCE you know where the bad ground or short is. Reading the wiring diagram is the hard part. They are so hard to read on japanese bikes.

so this red wire crosses this yellow wire, combines with this here brown wire, then separates again from this green wire. wait, what?

[butcher bergs]

Reading the wiring diagram is the hard part. They are so hard to read on japanese bikes.

Send me your e-mail addy. I'll show you a pic of what a pisser of a wire diagram looks like.

EDIT: Actually, you get picture texts?

[Catach]

Yeah, it's an easy fix ONCE you know where the bad ground or short is. Reading the wiring diagram is the hard part. They are so hard to read on japanese bikes.

exactly! the problem with electrical shit is that the problem could literally be ANYWHERE

[butcher bergs]

exactly! the problem with electrical shit is that the problem could literally be ANYWHERE

Start with what's borked and work backwards through the various wires and electrical components related to the circuit. It's only a motorcycle.

[F4Iguy]

Start with what's borked...

did he just say "borked"?

[Slyder]

Well, one thing I've noticed is some bikes really don't like to get wet. I avoid rain like the plague and anytime I get caught in the rain, I think "gee can't wait to see what wire in what harness cooks itself"

Been there done that too. The quickest easiest fix I've found was look at the harnesses, find the burnt wire(s) snip the bassards, strip, twist, wire nut, avoid rain.

When I wash the bike even, the key stays off and it gets pushed back into the hanger...that happens to have a dehumidifier....that gets turned up

[butcher bergs]

Holy shit!! A twist and a wire nut?



This thread is going to kill me!

[Catach]

Well, one thing I've noticed is some bikes really don't like to get wet. I avoid rain like the plague and anytime I get caught in the rain, I think "gee can't wait to see what wire in what harness cooks itself"

Been there done that too. The quickest easiest fix I've found was look at the harnesses, find the burnt wire(s) snip the bassards, strip, twist, wire nut, avoid rain.

When I wash the bike even, the key stays off and it gets pushed back into the hanger...that happens to have a dehumidifier....that gets turned up

personally, I'd rather fix my bike than not ride it.