Hello, I am new to the forum but i am very familiar with 600RRs especially 03-04, 05-06.
Having said this i have learned how finicky this particular system is and the trouble that comes with diagnosing the electrical system. I have researched the problem extensively and tried everything they suggested. I have the user manual and the equipment to do the tests etc.
I have power and the bike turns over.
The fuel pump primes, relay clicks
There is power to the coils, no spark.
Things i have checked/etc:
-Ignition is correct (has zener diode), Pink wire has 9volts reference
-Main Grounds are tested and good
-Battery has voltage and is not undercharged
-ECM power and ground lines tested good, Black/white has power, Grounds have continuity
-All safety components checked for operation and continuity, they work
eliminated to verify.
-Replaced Crank sensor, Replaced Killswitch, Replaced ECM, No Difference
-Tested with two different harnesses, No difference Tested with different sub harnesses, No difference
-Through inspection of all connectors,connections, wires etc, looks intact/solid
Question #1: Is the Black/White wire supposed to be grounded by ECM, Should it have power or be grounded when plugged in??? CAN SOMEONE VERIFY ON THEIR BIKE???
Question #2: At the coils, BOTH the colored wired side AND the black/white side have power!!! IS THIS CORRECT??? Or should there be power/ground?? OR is the spark plug the ground??
Question #3: On the dash, before starting, SHOULD THE FI LIGHT STAY ON AFTER THE PUMP CYCLES, OR DOES IT GO OUT?? (My FI light goes out)
***Side note: (With the Engine sub harness disconnected it stays on)
Question #4: How many times should the fuel cut relay click?? (MINE CLICKS TWICE)???
Question #5: When checking for power and ground at the safety switches, they are all grounded, Is this correct or should there be power/ground.
Question #6: When i check continuity at the killswitch, the book says there should only be continuity at certain wires when the start button is pressed or free . only one wire is giving me the proper reading, Blue/White) All the others have it pushed or free doesn't matter. IS THIS CORRECT?
I have also had weird readings coming from neutral line, oil pressure line, the safety system circuit and the brake light circuit. Some have power on both sides, Some are grounded both sides. This would tell me there is a short but i have checked and nothing. Plus it happens with both harnesses, computers, kill switch etc. Other things i noticed are the system drops about three volts when cranking, Theres a weird 5 volt reference when checking continuity on some of the engine sub harness components.
If I can have some of my questions answered i would really appreciate that, it would give me a better idea of what I'm dealing with. If you have any insight or have been through the same issue i could really use the help. Thank you for your time!!