GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 05, 2007 03:51 PM
Installed FE and did jumper, now no start--HELP
Today I put on my Comp Werkes FE, had no difficulties, but now it won't start. I also did the jumper mod this morning with a butt-end splicer. I spliced the black/yellow with the Turquois/green stripe with gold dots. After i did this, the bike fired right up, no problem. So I did the FE, all the lights work properly, turn signals, brakes, etc. But the bike just cranks, no start. So far I have:
Removed the splicer
Checked the fuses under the fairing by the fork, including the ECU fuse.
Has gas
Is in neutral
Checked main fuse
Kill switch on
Everything works fine, and it cranks like a champ, but ti won't turn over.
Does anyone have any ideas as to what could be wrong?
I'm getting very frustrated.
Thanks
  
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ridgeracer
Pro
Posts: 1309
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posted September 05, 2007 04:24 PM
 Edited By: ridgeracer on 5 Sep 2007 17:28
What year is it?
When you first turn on the key do you hear the the usual noises, fuel pump, exhaust servo?
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 05, 2007 05:01 PM
It's an 07, 1 month old, 1145 miles. Yeah, I hear the servo and I think the fuel pump, there is also a click by the battery I never heard before, but this is the first time I've started it with the seat off.
I also tried giving it throttle when I started it, didn't help. It's weird, everything seems to be functioning normal except it won't start.
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ridgeracer
Pro
Posts: 1309
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posted September 06, 2007 06:17 AM
I have an '06 but I'm pretty sure the '07 isn't radically different....
The starter circuit is independent from the Engine Control Unit (ECU). In other words the starter doesn't need the ECUs permission to crank over. What the ECU controls is the fuel via the fuel pump relay. If the ECU thinks the bike shouldn't start or be running it turns off the fuel pump relay.
Normally when you turn on the key the fuel pump comes on for a couple seconds during which time you'll here the injectors chatter as the each give two or three pulses of fuel to prime the engine then the fuel pump shuts off. Then when you press the starter button and the engine starts spinning the crank and cam sensors send pulses to the ECU and it turns the fuel back on.
So one of two things is happening. The fuel pump relay is on while the starter button is pressed or it is not. If it is not you need to find out why the ECU doesn't think the bike should start. I'd be looking for a wire harness connector that you unplugged or wire harness wires that got pinched against the frame when you installed the fender eliminator. Pinched wires can either break internally or short to ground against the frame. You may have to take the FE kit off and check for any smashed wires. If the ECU doesnt want the bike to start its because some input is missing. Usually however this would cause an FI light to blink and tell you whats missing.
If the fuel pump relay is on then the ECU is trying to start the bike but either the injector signals or coil signals are not getting through. Maybe you lost a ground somewhere or again something got unplugged or pinched.
Either way I think you need to remove the FE and look up under there for loose connections or pinched wires.
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 06, 2007 07:26 PM
Thanks. I'll go through that tomorrow, but I did check for disconnected plugs, pinches etc already. I will check closer. I did have to drill because my plate holder is under the seat, and you need a small hole to run the license plate light up to the harness. I did not look to see if I nicked a wire there, but I don't know what wire would be running between the underside and the underseat, but I'll check tomorrow.
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fish_antlers
Administrator
The Truth is Out There
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posted September 06, 2007 07:41 PM
make sure you've got the right wires! (triple check!!)
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What business is it of yours where I'm from, Friendo?
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 06, 2007 09:26 PM
The only wires I had to cut and splice were for each turnsignal and the license plate wire. I cut the wires off at the light and spliced it to the new lights and used the original pin connector, The brake light was not changed. When I did the jumper mod, I used a butt-splice connector and put it on the black/yellow wire and the turquoise/green stripe/gold dot. It started after I did that. I started it but shut it down after only a few seconds of running, so maybe the plugs did foul. This was BEFORE I did the FE.
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fish_antlers
Administrator
The Truth is Out There
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posted September 06, 2007 09:33 PM
If you've followed the instructions correctly there should be no problem... don't know what to tell ya!
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What business is it of yours where I'm from, Friendo?
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Lucky Lo
Moderator
I gotta go....
Posts: 677
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posted September 06, 2007 10:16 PM
check to see if you've got spark.
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 07, 2007 11:22 AM
Hey thanks for your help...mystery solved. I'm an idiot. I drilled through the ECM and not just that I hit the 34 pin connector which you can't even buy w/out buying the whole harness. I did not know the ECM was where it is, it looked like fender. I wish I would've looked closer, In addition, to get the ECM out is a real pain.
Thanks for everyones help.
New ECM=$735. New pin connector=unavailable.
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princesskiwi
Administrator
MISTRESS of SMACK
Posts: 7688
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posted September 07, 2007 09:08 PM
Are you serious?
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carlgar_04
Parking Attendant
Posts: 19
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posted September 07, 2007 10:30 PM
OH shit NO way. let me look in to it.
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C.G
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 08, 2007 05:00 AM
yeah, I'm serious. I am so mad at myself. I found a harness for $70+$20 shipping on ebay. I'm going to get that and splice in the wires for the connector. Now I hope to find an ECM used. It never dawned on my that the ECM would be where it is. It's wrapped in a rubber cover, held in a metal retainer (That is a bitch to get out--drop exhaust)underneath quite a few wire bundles(turn sig,brake,lic plate, jumper, a couple others), all under the back brace for the seat. I never saw it. The directions for the FE did say to drill in the "indentation" on the undertray, and there is a slight indent under there that would've cleared the ECM if I'd followed the directions. Somehow it didn't register when I was doing it. I got excited to get the FE on and didn't pay attention. Lesson learned.
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 08, 2007 05:04 AM
pictures aren't real clear, but you get the idea
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princesskiwi
Administrator
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posted September 08, 2007 09:23 AM
Awwww.... poor bike!
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fish_antlers
Administrator
The Truth is Out There
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posted September 08, 2007 09:23 AM
wow.... shitty! On the plus side, you might want to donate your damaged unit to RidgeRacer for his reprogramming project (see here- http://www.bikeland.org/board/viewthread.php?FID=1&TID=23797&pagenumber=11 )
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What business is it of yours where I'm from, Friendo?
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 08, 2007 09:59 AM
quote:
Awwww.... poor bike!
yeah and I have to send th e first payment Monday. I may have to buy a new ECM but I am striking out on the 34 pin connector.
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fish_antlers
Administrator
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posted September 08, 2007 10:12 AM
from your fotos it looks like the ECM is okay... just the connector on it damaged?
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What business is it of yours where I'm from, Friendo?
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 08, 2007 10:21 AM
nah, the drill bit took out a bunch of the metal pins that go into the connector, as well as some of the orange base around the pins. The inside of the ECM is fine, but can't be used. I don't know how you could fix the connector, but I didn't get the board inside or anything.
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fish_antlers
Administrator
The Truth is Out There
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posted September 08, 2007 10:27 AM
then you should seriously look at the link I sent you and donate the damaged unit to RidgeRacer (go to the beginning of that topic and you'll see why)
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What business is it of yours where I'm from, Friendo?
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princesskiwi
Administrator
MISTRESS of SMACK
Posts: 7688
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posted September 08, 2007 11:10 AM
DONT PANIC!!!
- get in contact with RidgeRacer - he is really smart and he could save you A LOT of $$$
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 08, 2007 12:23 PM
I sent him a pm with my sad story.  I didn't read the whole thread, just the first page, I have dial-up and it would take awhile). Anyway, when I get a new ECM, new or used, I'll certainly donate mine. I'm still looking for a used harness too. I'm not panicing, but I'm hoping to not drop a grand for my stupidity, and as goofy as it sounds, riding days are getting shorter here in the Lake Erie snowbelt and I was just getting addicted to those 10k to 16k pulls on the Kawi now that's it fully broken in!
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ridgeracer
Pro
Posts: 1309
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posted September 08, 2007 03:24 PM
Edited By: ridgeracer on 8 Sep 2007 16:26
You've got mail.
BTW does anyone have a pin out for an '07 ZX-6 ECU so we can see which pins got chewed up?
OH, AND DON'T CUT ANY WIRES YET!
If your connectors are like mine you can pull the undamaged pins out of the connector and re-insert them in a new connector. That will be a lot less hassle than splicing all 34.
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GOODTIMESROLL
Parking Attendant
Posts: 19
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posted September 08, 2007 04:23 PM
Thanks Ridgeracer. The orange plastic where the pins go got chewed up by the drill bit, you can't tell where the holes were. I haven't cut any wires yet...but the ones that got destroyed I am pretty sure control spark and ignition since the bike had fuel but no spark. With the 34 pin plug, it got pretty mangled too. It's hard to tell from the blurry picture, but the plastic is gone. I will have to have the bike 5 years as I am just making my first payment...so I really think I'm going to have to get a new or used ECM, and probably the harness so I don't have warranty issues down the line as well. I purchased the 4 year warranty that takes over after the first year. I will be happy to donate my damaged one to you so it can 'further the cause". Thanks everybody.
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crip2nite
Zone Head
Posts: 820
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posted September 10, 2007 12:19 AM
I went to the auto parts store and bought a simple fuse to use for the jump instead of a flimsy wire on my 636. I definitely feel the extra HP at 13,000...
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'08 ZX-10R ~ GREEN ~
Long Island, NY
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