07 CBR600 Heavy Load Cut-offs - 600RR.net
Troubleshooting Having trouble with your bike? Common know issues or trobuleshooting questions here.

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post #1 of 51 (permalink) Old 01-21-2015, 12:12 PM Thread Starter
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07 CBR600 Heavy Load Cut-offs

Hi peeps,
Iím hoping one of you may have come across this issue and may be able to assist.
I will start with bikes overview and work my way to the fault in the shortest method possible.


Bike: 2007 Honda CBR600RR
Mileage: ~80,000 miles
Recent Services: Oil, Chain, Clutch, Valves, Filter Cleaning, Throttle Cable replace (Due to at-fault tear).
Known Missing Part: My bike, during one of my service, I lost 3 of 4 Injector Seal Rings that are above the airbox. I will be replacing these this weekend but theyíve been missing for over 2,000 miles now and this issue occurred yesterday.

Issues/Fault:
So, my bike was running perfectly fine. Although more recent, in the morning it has a rough time keeping the idle at a higher level to assist with warming up, but this isnít the issue Iím encountering. The issue was noticed on my way from work when the bike would have a momentarily stall out during acceleration. So during acceleration and low rev RPMís the bike would have a 1 second cut off/cough. The bike is running, the cut off is too short to notice if the engine is shutting off or if itís just slipping out of gear. It seemed to be what feels like a slipping clutch, but the clutch is 2,000 miles new.

So to put it in short, this is occurring under HEAVY loads on the throttle, the bike coughs or possible even cuts off for approximately a second and picks back up.

I hope this is detailed enough to help some of you with giving me possible diagnostics based on this. No fault codes trigger and nothing on the gauge changes during this occurrence.
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post #2 of 51 (permalink) Old 01-21-2015, 12:22 PM
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Well at first it sounded like an issue with Air/fuel mixture and the signals being sent to the bikes computer. Which would sort of explain the difficulty idling. but you also mentioned another issues which was under heavy load on the motor it would cut out. What are the most recent things that have been done to the bike recently?

1. Have you replaced the missing seals?

2. Did you check the clutch?

If the bike was working fine before these services were completed, then I would start there and see if there is an issue, if not then move on to the next item. There are a crap ton of other threads that are similar to yours. They mention possible Intake Air Temp sensor issues, dirty air filters, bad wires, etc. you have to track down the gremlins one step at a time. Good luck and God Speed.

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Last edited by Jericho87; 01-21-2015 at 12:24 PM.
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post #3 of 51 (permalink) Old 01-21-2015, 12:54 PM Thread Starter
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Hi Jericho,

Thanks for your response. This issue appears to have happened out of random. Although the clutch was replaced 2000 miles prior to this issue, and the injector sealers missing 1,000 miles ago the issue wasn't present until last night. I ordered the Injector seals but haven't yet replaced them. Plans to do so by this weekend.
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post #4 of 51 (permalink) Old 01-22-2015, 03:40 PM Thread Starter
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I rode all night last night and not a single stall-out. It ran perfect. I want to say, possible bad fuel?
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post #5 of 51 (permalink) Old 02-01-2015, 12:58 AM
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maybe?

where do you buy your gas? (i buy from the same station 95% of the time).

I buy gas from good clean (Shell) stations...particularly when i am out of my local area.

may i suggest some fuel/injector cleaner?
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post #6 of 51 (permalink) Old 02-08-2015, 02:05 AM Thread Starter
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It stopped for a while but now I notice anything about 11k the bike has trouble increasing on RPM. Pretty much it treats 11k like redline. 4k too early.

I plan on running injector cleaners. Could this be even a possibility?
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post #7 of 51 (permalink) Old 02-08-2015, 09:24 AM
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Injector cleaner may help, but if they are truly dirty a professional cleaning will be the best way to get them really clean.

Honestly, I'm thinking fuel pump (and fuel filter). All the symptoms are there so I'd grab my service manual and do the flow test to see for sure but it sounds like that's the issue.

On a bike with 80k, I'd say it's a pretty good bet it's got some wear on it especially if the bike is ridden with under a quarter tank luel level often.

Mike
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post #8 of 51 (permalink) Old 02-09-2015, 07:35 AM
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Don't bother with injector cleaner, it's just snake oil. If you want your injectors cleaned, arrange to have them done professionally instead of with some silly additive.

My guess is that your fuel pump is on it's way out.
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post #9 of 51 (permalink) Old 02-09-2015, 03:12 PM Thread Starter
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Hm. I didn't even consider a faulty fuel pump. Now I saw some of you mentioned that I should do a fuel flow test. I take that this allow me to find out if the fuel pump is truly defective before replacing the parts, correct?
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post #10 of 51 (permalink) Old 02-11-2015, 06:23 AM
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Nope. Flow test doesn't happen at pressure.

They will quite regularly pass the flow and pressure tests but still be faulty.
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post #11 of 51 (permalink) Old 02-16-2015, 12:00 AM
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Gotta say it sounds like what I had after I got my brothers bike that sat for 4+ years. Check fuel pump fuel filter and make sure u don't have rust in your tank. Also if you have a power commander on the bike. Get it tuned. That's what cause my bike to do that to me. Good luck. Keep us informed.
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post #12 of 51 (permalink) Old 02-17-2015, 07:20 AM
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Last year, my bike with 75K+ miles had the same issue at the track. Would pull fine until 11K RPM, then felt like an anchor was tossed out the back and wouldn't increase RPM. Swapped out the fuel pump, and ran like normal.

Not sure on the 07+, but on the 03-06 you can remove the mesh screen, clean it, and reattach it to see if it improves things.

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post #13 of 51 (permalink) Old 03-02-2015, 05:29 PM Thread Starter
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Quote:
Originally Posted by cbr6racr View Post
Last year, my bike with 75K+ miles had the same issue at the track. Would pull fine until 11K RPM, then felt like an anchor was tossed out the back and wouldn't increase RPM. Swapped out the fuel pump, and ran like normal.

Not sure on the 07+, but on the 03-06 you can remove the mesh screen, clean it, and reattach it to see if it improves things.

Yep I replaced it with a new/used fuel pump, replaced the ECM (temporary) and the problem was still occurring. With the new ECM, it didn't do it for a while but then it started right towards the end of my testing. I'm running out of ideas as to what this could be.

I've even ran SeaFoam to make sure everything running clean and smooth. Any more suggestions guys?

I find it hard to believe that I could have two defective fuel pumps. My OEM tank is dented due to a ventilation issue, but the dents have been there for 50k+ miles and no issues since.
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post #14 of 51 (permalink) Old 03-02-2015, 06:16 PM
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I missed it; When did you replace your coil packs?

'07 CBR600RR Track-Only Demon!
Nesba/N2/PRE/TPM/Roger Lyle "A" Group // CCS #306

'08 GSXR 600 Blue ~ Current Bike
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'08 GSXR 600 White ~ SOLD
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post #15 of 51 (permalink) Old 03-02-2015, 06:25 PM Thread Starter
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Quote:
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I missed it; When did you replace your coil packs?
never replaced them. Is that a scheduled service?

Last edited by fezz; 03-02-2015 at 06:42 PM.
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post #16 of 51 (permalink) Old 03-03-2015, 01:08 PM Thread Starter
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Could it be a bad/loose pick up coil?
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post #17 of 51 (permalink) Old 03-03-2015, 04:59 PM
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Quote:
Originally Posted by fezz View Post
never replaced them. Is that a scheduled service?
Quote:
Originally Posted by fezz View Post
Could it be a bad/loose pick up coil?
It is not a Scheduled service but they are wearable item. I would inspect them personally.

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'07 Yamaha R6 Blue ~ SOLD
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post #18 of 51 (permalink) Old 03-03-2015, 05:16 PM
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Another thing that comes to mind for your idling issue is all the following: Throttle Bodies w/ IACV (distribution hose leaks?), IAT, MAP sensors.

'07 CBR600RR Track-Only Demon!
Nesba/N2/PRE/TPM/Roger Lyle "A" Group // CCS #306

'08 GSXR 600 Blue ~ Current Bike
'07 Yamaha R6 Blue ~ SOLD
'08 CBR600RR Silver ~ SOLD
'06 Yamaha R6 Black ~ SOLD
'08 GSXR 600 TrackOnly ~ SOLD
'08 GSXR 600 White ~ SOLD
'08 Yamaha R6 ~ SOLD
'07 GSXR 750 ~ SOLD
'12 Aprilia RSV4 Factory ~ Crashed/SOLD
'07 CBR600RR Black ~ SOLD
'09 CBR600RR Phoenix TrackOnly ~SOLD
'09 CBR600RR Red/Black ~SOLD
'07 CBR600RR Blue/Silver ~SOLD
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post #19 of 51 (permalink) Old 03-04-2015, 10:56 AM Thread Starter
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Quote:
Originally Posted by crashkhanman View Post
Another thing that comes to mind for your idling issue is all the following: Throttle Bodies w/ IACV (distribution hose leaks?), IAT, MAP sensors.

I feel these would trigger the FI light, if you disagree, please let me know :)
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post #20 of 51 (permalink) Old 03-04-2015, 11:52 AM
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Quote:
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I feel these would trigger the FI light, if you disagree, please let me know :)
The service manual implies its hit/miss as to whether it would trigger the Fi light and they say the IACV could use inspection/cleaning. Also; a tiny leak in the distribution hoses would cause poor idling but not trigger the Fi light.

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'08 GSXR 600 Blue ~ Current Bike
'07 Yamaha R6 Blue ~ SOLD
'08 CBR600RR Silver ~ SOLD
'06 Yamaha R6 Black ~ SOLD
'08 GSXR 600 TrackOnly ~ SOLD
'08 GSXR 600 White ~ SOLD
'08 Yamaha R6 ~ SOLD
'07 GSXR 750 ~ SOLD
'12 Aprilia RSV4 Factory ~ Crashed/SOLD
'07 CBR600RR Black ~ SOLD
'09 CBR600RR Phoenix TrackOnly ~SOLD
'09 CBR600RR Red/Black ~SOLD
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Last edited by crashkhanman; 03-04-2015 at 11:58 AM.
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post #21 of 51 (permalink) Old 03-04-2015, 11:57 AM
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To make following this post easier: Can you re-list: Current Symptoms / Troubleshooting performed thus far / Mileage when performed / current mileage?

'07 CBR600RR Track-Only Demon!
Nesba/N2/PRE/TPM/Roger Lyle "A" Group // CCS #306

'08 GSXR 600 Blue ~ Current Bike
'07 Yamaha R6 Blue ~ SOLD
'08 CBR600RR Silver ~ SOLD
'06 Yamaha R6 Black ~ SOLD
'08 GSXR 600 TrackOnly ~ SOLD
'08 GSXR 600 White ~ SOLD
'08 Yamaha R6 ~ SOLD
'07 GSXR 750 ~ SOLD
'12 Aprilia RSV4 Factory ~ Crashed/SOLD
'07 CBR600RR Black ~ SOLD
'09 CBR600RR Phoenix TrackOnly ~SOLD
'09 CBR600RR Red/Black ~SOLD
'07 CBR600RR Blue/Silver ~SOLD
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post #22 of 51 (permalink) Old 03-05-2015, 11:33 AM Thread Starter
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Quote:
Originally Posted by crashkhanman View Post
To make following this post easier: Can you re-list: Current Symptoms / Troubleshooting performed thus far / Mileage when performed / current mileage?
Symptoms:

I will list all symptoms, some of which are not concerning and the major symptoms. The minor symptom is at cold starts, the bike revs normally but 30 seconds later the idle drops while the bike is still cold and it warms up on what appears to be normal running but rough idle, it smoothens out once warm. If this issue isn't related to what is listed below, then fixing this wouldn't be a concern to me.

The major concerning symptoms is what I call the cut-off on High Revs/Heavy Loads. This occurs about 75% of the time and at other times it runs normally. When accelerating aggressively to higher rev's the bike hesitates to go above 11,000 revolutions. The hesitations works in a matter where it appears the engine cuts-off for a short moment less or equal to 1second or typically acts as a rev limiter but it bounces past 11,000RPM but it is a mess anything above 11,000RPM, if I can get it past. The bike currently has 80,600 miles on the odometer.

Troubleshooting/Repairs

This issue became much more relevant after the clutch was changed out. However, the issue existed before the clutch work but was very rare and minor. This recently made me believe that it could be a bad pick-up coil since it's attached the the clutch cover.

I recently replaced the fuel pump with a used one purchased from eBay (80,200 miles). This didn't appear to fix anything. I then followed with replacing the ECM with one from another bike (1-year newer model <2008>, same day as the fuel pump). Issue seemed less relevant but it did it, so this goes back to the 75% of the time this occurring. So that ruled out on being a bad ECM.

After doing further research online, I see people claiming that it could be a bad fuel line, bad/loose pick-up coil, or a cam chain issue. A mechanic locally had informed me that it could be the Main Harness or ignition coils. With my cam chain I have the manual adjusting cam chain tensioner if this helps in anyway of troubleshooting this issue. I've had the manual cam chain tensioner for over 40,000 miles now. I began noticing this issue as it became more relevant, I would say this issue was noticed for about 2,000 miles now, clutch was changed 4,000 miles ago. However, I didn't ride the bike hard for the first 2,000 miles, no particular reason, so it's hard to know if this issue happened immediately after the clutch or at a later time.

I hope this is detailed enough and hopefully I can get some more suggestions. Any helps as I'm completely lost as to where to diagnose.
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post #23 of 51 (permalink) Old 03-05-2015, 01:25 PM
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And there's a slew of TS steps and parts under PGMFI testing.....

What state are you in?


'07 CBR600RR Track-Only Demon!
Nesba/N2/PRE/TPM/Roger Lyle "A" Group // CCS #306

'08 GSXR 600 Blue ~ Current Bike
'07 Yamaha R6 Blue ~ SOLD
'08 CBR600RR Silver ~ SOLD
'06 Yamaha R6 Black ~ SOLD
'08 GSXR 600 TrackOnly ~ SOLD
'08 GSXR 600 White ~ SOLD
'08 Yamaha R6 ~ SOLD
'07 GSXR 750 ~ SOLD
'12 Aprilia RSV4 Factory ~ Crashed/SOLD
'07 CBR600RR Black ~ SOLD
'09 CBR600RR Phoenix TrackOnly ~SOLD
'09 CBR600RR Red/Black ~SOLD
'07 CBR600RR Blue/Silver ~SOLD

Last edited by crashkhanman; 03-05-2015 at 01:27 PM.
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post #24 of 51 (permalink) Old 03-05-2015, 09:27 PM Thread Starter
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Quote:
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And there's a slew of TS steps and parts under PGMFI testing.....

What state are you in?

I'm in California. What is that attached document, I'm having trouble understanding it and applying it to my issue
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post #25 of 51 (permalink) Old 03-06-2015, 01:08 AM
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That my friend is from the troubleshooting section in the service manual. I am surprised you don't recognise it.

Not sure if it will help you solve your problem, but that page crashkhanman has shown you and this following one I hope can lead you somewhere, it's relevant to your issue:





You should be able to find this manual on the internet...I suspect you will need the whole manual if you are to follow through with some of the "checks", unless you happen to know how to do all of it without looking it up.

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2006 Honda CBR600RR
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post #26 of 51 (permalink) Old 03-06-2015, 08:18 AM
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Couple people with older, higher mileage bikes have reported problems with the ignition coil packs (was mentioned earlier) and their connections to the spark plugs. Might want to pull plugs and look at the top to see if they are grooved.

Used coil packs shouldn't be too expensive. Search on the forum for the issue, should be some pics of what the bad stuff looked like.

The only othe thing I'll mention is the used fuel pump; not saying it is bad but they can, and do wear out and have a finite lifespan. It's almost like buying used spark plugs, yeah they may work a while longer than what you have but you are probably better off buying a new.

I'd move on and try other things first because there seems to be no change in symptoms, but don't be hugely surprised if it turns out it was bad.
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post #27 of 51 (permalink) Old 03-09-2015, 04:24 PM
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My friend's 08 zx6r has EXACTLY the same symptoms, and has been struggling with it for a while over a month now, it has been getting worse just like you mentioned, I rode it and almost definitely feel its either fuel/air deprived. just today he found out his egcv is stuck (cables seem dried or damaged and the servo cant move them all the way)....its not fixed yet so I cant tell u if it was the culprit

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post #28 of 51 (permalink) Old 03-10-2015, 12:35 PM Thread Starter
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I've been curious whether it is the Exhaust Servo. Does your friends bike throw a FI/Check Engine Light when it cuts off? Usually it should on a defective servo, mine doesn't throw FI light so it hasn't been a prioritized concern.

I just bought a new/used ignition pulse sensor. Hoping it'll be the culprit.
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post #29 of 51 (permalink) Old 03-12-2015, 09:41 AM
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His bike has been throwing fi ever since I can remember as it has many badly done tweaks and repairs, I am not sure how the servo diagnostic works, but id assume it'll trigger FI if its either disconnected or due to internal resistance changes, so in case of a jammed cable it might pass fi diagnostic and still be acting up...
As for my friend's zx6r, he fixed the servo and it now pulls so hard up till 13500 rpm, beyond that he feels it lost some of its umph, but doesn't hit a wall anymore, so its fair to say that was it..better check ur egcv, might be it, and best of luck

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post #30 of 51 (permalink) Old 03-12-2015, 06:33 PM
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Phones acting weird, I will post from a comp.

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