03 600RR sputtering and won't idle - 600RR.net
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post #1 of 18 (permalink) Old 05-03-2014, 11:37 PM Thread Starter
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03 600RR sputtering and won't idle

I've read a couple other threads that have similar problems and still can't figure it out.

The bike ran fine before winter, but when I started it up recently, it wouldn't idle and sputtered really bad. I have to hold the throttle open while starting to get it to run. If I let go of the throttle, it will die.

So far I have replaced the plugs and adjusted the idle all the way up. I also siphoned as much gas out of the tank as I could and put fresh gas in with fuel injector cleaner. It has 13k miles with a PCIII and M4 slip on. I hope it's just an ignition coil.

Any help is greatly appreciated.


Last edited by soymilk; 05-04-2014 at 06:25 PM.
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post #2 of 18 (permalink) Old 05-03-2014, 11:41 PM
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Almost sounds like a miss.

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post #3 of 18 (permalink) Old 05-04-2014, 04:53 AM
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My 03 has started doing the same thing since I changed the exhaust, except mine doesn't cut out

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post #4 of 18 (permalink) Old 05-04-2014, 12:18 PM
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Jack - that can was fine on my bike.

Last edited by youngy; 05-04-2014 at 12:25 PM.
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post #5 of 18 (permalink) Old 05-04-2014, 01:20 PM Thread Starter
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Well, I sprayed water at each header coming from the cylinders and they were all hot. That means there's a spark but I guess it could be a weak spark. I'm going to have to pull the new plugs to see if there's anything on them. Should I get used ignition coils on ebay? They're fairly cheap.
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post #6 of 18 (permalink) Old 05-04-2014, 01:58 PM
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Hi Youngy, its not something I'm attributing to the exhaust, I freaking love it and so does everyone else. As it hasn't been stalling or anything else, it hasn't bothered me. I'm going to take the bike to Steve Jordan for a service and to get my suspension set up correctly, while I'm there I'll get them to check I did everything correctly

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post #7 of 18 (permalink) Old 05-04-2014, 02:50 PM Thread Starter
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I've read that it's possible for the throttle position settings in the PCIII to not be zero'd out and the fuel maps reset. The battery was out of the bike for a couple months.

I checked the map in the PCIII and it was all zeros. I tried the stock map and then a slip on map; it made no difference. Throttle position seemed ok. The smoke from the exhaust was really bad and smelled like straight gas. What could be causing this?

Last edited by soymilk; 05-04-2014 at 03:27 PM.
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post #8 of 18 (permalink) Old 05-04-2014, 03:52 PM
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a mouse nest in the airbox?
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post #9 of 18 (permalink) Old 05-04-2014, 04:03 PM
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Almost sounds like it's not getting enough fuel to stay running at an idle that's why when you Rev it than it stays running

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post #10 of 18 (permalink) Old 05-04-2014, 06:07 PM
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Sounds like air or fuel is getting restricted along the way.
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post #11 of 18 (permalink) Old 05-04-2014, 06:24 PM Thread Starter
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Quote:
Originally Posted by youngy View Post
a mouse nest in the airbox?
nothing in the airbox but a new air filter.

Quote:
Originally Posted by blkcavy98 View Post
Almost sounds like it's not getting enough fuel to stay running at an idle that's why when you Rev it than it stays running
I was thinking that too but the smell of fuel from the exhaust is so strong. I'm starting to think a few cylinders aren't firing. That would also cause it to not stay running at idle.

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Sounds like air or fuel is getting restricted along the way.
If fuel was restricted, it wouldn't smell like unburnt fuel coming out the exhaust right?
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post #12 of 18 (permalink) Old 05-04-2014, 07:48 PM
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Than the fuel isn't getting burnt which could be plug or coil. Or even wiring

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post #13 of 18 (permalink) Old 05-05-2014, 01:32 AM
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I suggest uninstalling the PCIII completely and see if it still runs rough. If not then it may be the O2 sensor and if that isn't it then it may be the TPS sensor.
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post #14 of 18 (permalink) Old 05-05-2014, 04:35 AM
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Originally Posted by Mr.Cannon View Post
I suggest uninstalling the PCIII completely and see if it still runs rough. If not then it may be the O2 sensor and if that isn't it then it may be the TPS sensor.
03 (over here anyway) doesn't have an O2 sensor, but I would take off the PC thing and try again.

OP when you changed the air filter did you disconnect the inlet air temperature sensor? is it connected correctly?
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post #15 of 18 (permalink) Old 05-05-2014, 04:41 AM
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Quote:
Originally Posted by soymilk View Post

I was thinking that too but the smell of fuel from the exhaust is so strong. I'm starting to think a few cylinders aren't firing. That would also cause it to not stay running at idle.



If fuel was restricted, it wouldn't smell like unburnt fuel coming out the exhaust right?
you already said you sprayed the headers and all cylinders seemed to be firing.

if the mixture is too weak to fire then it will go straight out of the exhaust. how long have you had this bike? you know the exhaust stinks on these things, right?

could be water in the fuel. try a cup of meths (denatured alcohol in the US) in the fuel tank. this will help evaporate off any water caught in the filter or injectors.
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post #16 of 18 (permalink) Old 05-05-2014, 05:52 PM Thread Starter
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Quote:
Originally Posted by youngy View Post
03 (over here anyway) doesn't have an O2 sensor, but I would take off the PC thing and try again.

OP when you changed the air filter did you disconnect the inlet air temperature sensor? is it connected correctly?
I did disconnect the temperature sensor but I reconnected it. It was running bad even before I changed the air filter though.

Now that a few people are suggesting I disconnect the PC, I'm going to do that. The PC is pretty old, so it could be that it failed even though the electronic fuel bars on it are working.


Quote:
Originally Posted by youngy View Post
you already said you sprayed the headers and all cylinders seemed to be firing.

if the mixture is too weak to fire then it will go straight out of the exhaust. how long have you had this bike? you know the exhaust stinks on these things, right?

could be water in the fuel. try a cup of meths (denatured alcohol in the US) in the fuel tank. this will help evaporate off any water caught in the filter or injectors.
I've had the bike for about 8 years and I know the smell you are talking about, but this smells like straight gas. I will give that denatured alcohol a try if disconnecting the PC doesn't work. Thanks for the advice.
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post #17 of 18 (permalink) Old 05-15-2014, 08:09 PM Thread Starter
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Finally warmed up outside. I figured out that the main cause of the problem was the PCIII. I disconnected it completely and the bike now idles steady. However, when I turn the throttle, it dies instantly. I made sure the TPS was connected because I did forget it at first the bike after reconnecting the original harness to the fuel injectors. It didn't really seem to make a difference if it was connected or not. Does this sound like a bad TPS?

I noticed the red oil/temp light and FI light stays on when the bike is running now. The fan instantly kicks on even though the bike is cold. I'm thinking that red light is on because the bike thinks its overheating. Some weird stuff is going on since I disconnected the PC.

Last edited by soymilk; 05-15-2014 at 09:43 PM.
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post #18 of 18 (permalink) Old 07-26-2014, 11:26 PM Thread Starter
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I found out that the ECU is not getting a reading from the TPS, MAP, IAT, and ECT sensors. These 4 sensors share a green/orange wire. Continuity is good to the ECU harness and the ECU was replaced with another used one. Still can't figure this out..


Edit: Problem solved! This solution is for anyone who may run into this problem in the future. Turns out my original and used replacement ECU were both fried. I suspected that it was my R/R because it did not test correctly with a multimeter, although it did charge the battery. I replaced it with an 05/06 R/R and installed a third ECU. Bike fired right up without any codes.

Last edited by soymilk; 08-17-2014 at 12:38 AM. Reason: Problem solved
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