Y2KZX12R
Needs a job
CompetitionCNC.com
Posts: 3762
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posted January 22, 2007 07:58 AM
You need to start with the basics.
Is it getting spark while cranking?
Is it getting fuel while cranking?
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Y2KZX12R
CompetitionCNC.com
   
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jus1975
Expert Class
Posts: 402
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posted January 22, 2007 11:49 AM
No spark or fuel. It will turn over.
Cannot clear codes from ECU.
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H2 to ZX12
Needs a job
two stroke power
Posts: 3674
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posted January 22, 2007 05:56 PM
painful read! 6 months of headache/heartbrake. have you dropped on you knees and prayed to the great God of Ninja. seriously, some spirituality could go a long way. maybe a chapter in zen and the art might help
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jus1975
Expert Class
Posts: 402
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posted January 22, 2007 06:04 PM
When I get a chance to mess with it again, I thought I would try that. It could not hurt. I look at it as a sign that it was not safe for me to ride this summer.
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Y2KZX12R
Needs a job
CompetitionCNC.com
Posts: 3762
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posted January 23, 2007 03:09 AM
Assuming all fuses are good and the grounds are good. (near map sensor)
You need to ck the crank shaft signal coil output.
Ck both connectors (where power commander connects). there may be a bent pin. visually ck them and then do a continuity check on each side of the connector. (disconnect battery first)
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Y2KZX12R
CompetitionCNC.com
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jus1975
Expert Class
Posts: 402
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posted March 07, 2007 07:41 PM
I'm back on the job. I tried clearing the codes again. No success.
I started checking for unusual grounds. I checked at the the connectors and pins for contunity to ground. I found one at the kill switch connector on the main harness side. The red and white wire. Tomorrow I was going to try tracing it back when I get my analog meter from a friend.
Do anyone know the phone number to Kawasaki customer service department.
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ridgeracer
Pro
Posts: 1309
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posted March 08, 2007 09:45 AM
You say you can't clear the codes. Can you expand on that?
Are you talking about the FI error codes from the ECU?
What codes are you getting?
Is it possible it only appears not to clear because you have not cleared the underlying condition that generates the code and it re-faults everytime you turn it on?
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jus1975
Expert Class
Posts: 402
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posted March 08, 2007 12:00 PM
The codes are 31-vehicle down sensor,malfunction,wiring open or short,
and 46-fuel pump relay stuck on.
Both these items have been checked and I went ahead and replaced them anyway.
I have tried clearing the codes by removing the negative and by removing the ECU. Without trying to start the bike I ca check the codes and they are still there.
Today I am going to start checking contunity again and checking if there is a ground that is not suppose to be there. I have already found a ground and the connector on the main harness side for the kill switch. Its is the red/white wire. What I will do is hook an analog meter to the ground and while looking at the meter start moving parts of the harness to see if the needle moves.
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ridgeracer
Pro
Posts: 1309
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posted March 08, 2007 03:12 PM
On the newer 32 bit ECUs you can not clear the code by removing power. I would check your 2004 manual self diagnosis section to see if it has a code clearing procedure.
On my '06 ZX-6 you have to put the ECU into dealer mode 2 and then hold the clutch in for 5 seconds to clear the codes. All these bikes ZX-6, 10, 12 ,14 share the same base 32 bit ECU. I can't swear your '04 zx-12 is the same procedure but I think its worth checking the manual.
Also have you tried putting your ECU into dealer mode 2? By just grounding the diagnostic lead it goes into dealer mode 1 which shows the saved (old) codes. In dealer mode 2 it shows the real time (now) codes. It would be interesting to see what the real time codes, if any are.
You know of course that a bad vehicle down sensor would cause the exact problem your seeing; crank but no ignition/injection. Did your FI light start flashing right after you jumped it or is that something that has only started recently?
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ridgeracer
Pro
Posts: 1309
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posted March 08, 2007 04:29 PM
quote:
I have already found a ground and the connector on the main harness side for the kill switch. Its is the red/white wire. What I will do is hook an analog meter to the ground and while looking at the meter start moving parts of the harness to see if the needle moves.
The way I read the schematic for the zx1200-B3 (that is your bike?)...
The 'kill switch' next to the starter button has no ground connection. One side is connected to the 10 Amp ignition fuse and the other powers the starter button, the positive side of the fuel pump relay, and the positive side of the coil sticks.
It would seem to me that if you did have an intermittent ground on that circuit it would pop the Ignition fuse.
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jus1975
Expert Class
Posts: 402
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posted March 08, 2007 08:58 PM
I didn't get a chance to fool with the bike today. Hopefully tomorrow. Unless I have been looking at the 02 manual, it stated to remove the codes yo have to remove the ECU. I have been using the dealer code 2 mode. In dealer 1 mode it shows nothing. I haven't looked at the schematic yet but if it goes to the fuel pump relay and the positive side of the coil packs then it may be a short along those paths. Maybe a common place where they meet.
Thanks for that information. I will have to check that out.
I dont think I replace the harness for the coil packs. I know I replaced the main harness and sub harness, along with, the vehicle down sensor and fuel pump relay.
But thanks for your help. I need all I can get.
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jus1975
Expert Class
Posts: 402
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posted March 09, 2007 04:31 PM
I played with the bike for a little while today. I had previously discovered a ground that should not have been. I the pin o the right side switches on the harness side to the ground on the frame on the left side. It only went away when I unpluged the junction box. I am going to check the junction box later. I also noticed that the ignition harness is melted together from some heat. i didn't replace that so I guess that will be next. I will check the pins in that harness just in case.
I want to thank you guys for the help you have given me so far. I'm not out of the water yet so don't leave me hangin.
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jus1975
Expert Class
Posts: 402
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posted March 21, 2007 05:54 PM
Thanks to everyone that helped in solving my problem. I replaced the ingnition switch and the bike started. It will not stay running but I believe that may be bad gas. I will siphon the fuel out tomorrow and try it again.
Once again
THANKS!!!!
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wirral_biker
Parking Attendant
Posts: 11
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posted March 22, 2007 09:33 AM
Phew - thank God !!!!
Seriously, well done !!
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eastbaydave
Needs a job
Posts: 2245
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posted March 22, 2007 12:45 PM
quote:
Thanks to everyone that helped in solving my problem. I replaced the ingnition switch and the bike started. It will not stay running but I believe that may be bad gas. I will siphon the fuel out tomorrow and try it again.
Once again
THANKS!!!!
Throw some Stabil into it...(water displament), & some injector cleaner (Techron/Chevron I like.)
I didn't see it mentioned....clutch switch? I had a bad contact (goop on inside of switch) that bugger drove me nuts!!! (I know, not a long drive...) :P
Glad to see your getting closer...been following this but didn't have anything to offer early. Best of luck & keep us updated....
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Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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jus1975
Expert Class
Posts: 402
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posted March 22, 2007 08:39 PM
Well come to find out, I had replaced the crank sensor with a brand new, out the box, bad sensor.
Just luckly, during my replacing parts stages, I had order one by mistake. So I had a another new sensor. The bike runs fine.
Thanks again to everyone involved.
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VincentHill
Needs a life
Posts: 6520
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posted March 23, 2007 04:37 AM
WOW!! OH MAN 0 MAN! This has to be the RECORD problem of not starting in the WORLD! I could not believe that this was the same thread since September! Do us all a favor and add up what you spent in "MONEY" (No one wants to know the Hours and heart Ache). FISH, Send him a "T" Shirt on me! (PM me with the amount and address. He is what this board is all about!
Great Going Guy! You really hung in there! I hope you bought a batter Charger (1 to 10 Amps Max with the Deep cycle charge) and never jump it again!
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ninja12
Needs a job
Posts: 3310
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posted March 23, 2007 01:14 PM
Do you think the jump killed the crank sensor or just bad luck when it died?
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jus1975
Expert Class
Posts: 402
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posted March 25, 2007 11:08 AM
It may have killed the first crank sensor but the second one was bad out the box.
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MAXIMUS
Needs a job
Posts: 4156
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posted March 25, 2007 03:32 PM
Dam it was about time, im happy for you just, hopefully now you can get some riding in instead of working on it.
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jus1975
Expert Class
Posts: 402
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posted April 14, 2007 02:29 AM
I just want to say thanks to everyone here. Sorry i didn't get back with you guys sooner but I have been riding. How do you post pics.
I appreciate the offer Vicent but I would rather not think about the money. It could make you sick.
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H2 to ZX12
Needs a job
two stroke power
Posts: 3674
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posted April 17, 2007 10:21 AM
good job, most would have left it sit or sold the beast by now.
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g_right
Novice Class
Posts: 84
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posted April 19, 2007 04:43 AM
H2 to ZX12... We ZX12 owner's are just like CLEVELAND BROWNS FANS!!!!! WE DON'T GIVE UP!!!!!!!
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speedgene
Zone Head
Posts: 996
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posted April 20, 2007 03:27 AM
Crank sensor has no code to spit at you to say, "Change me"... or check me out, (at least). I bet you know that 12 better than most.... jus1975. I'm HAPPY for you! You're riding again.
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E-tard
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