Found The Culprit
Worked on my 2006 ZX-6R again today and now I am armed with a service manual I downloaded online. I love the internet! This PDF manual is pretty cool because the wiring diagrams are detailed. So I retraced the wire all the way down to the ECU. Using my ohmmeter, I toned out the red wire coming from the kill switch against the frame (ground) and there is the problem. It is shorted! I did more test and turned out that I only get continuity when the smaller connector of the ECU is plugged in. I disconnected all loads and only left the ECU and tachometer, which is a pretty good isolation. Fuse still blows up with the ECU connected. So at that point, I concluded that the ECU has a short inside. I already ordered an ECU on Ebay just a few minutes ago.
Henry,
Ive been reading your post about this bike because I have the same problem. My ecu fuse blows when the key is turned if the kill switch is on. If the kill switch is at off when the key is turned, the fuse blows when I start the bike. I checked the wiring and cannot seem to find any visible shorts. My friend also checked the wiring with an ohmmeter and couldn’t find anything. Hes pretty good at that so I would trust him on it. I figured its the ECU and ordered another one on eBay. It came and when I plugged it in, the bike turned over two separate times (and then died because it hasnt been on in a long time). On the third time it blew the fuse again.
Do you think the bike is shorting the ECU? Is there anything else you can recommend for me to check? You seem like you really know what you’re doing so I decided to ask you. Hopefully you still check this and get back to me.
Thanks
Anton
devantmarketing@gmail.com (preferably the one that I submitted above though, I dont know if you see it or not)
Los Angeles
Hey Anton. I’d recommend you to try to isolate everything. Disconnect all the load including all the relays and connect them one at a time and turn the ignition key to on without cranking it. I know it’s a long process but it’s a sure way to find out which part is blowing the fuse. Also, charge your battery
And make sure you have plenty of 10A fuse for testing.
If you can read a wiring diagram, then that will help you even more. Let me know how it goes.
Thanks, I will check it out tonight or tomorrow. Meanwhile, I realized I wasn’t completely accurate in my description of the problem. The bike will turn over freely but wont actually start (I realized my mistake when you mentioned the battery). The battery is new and charged well, I’ve checked it.
What I meant to say was that when I put in the new ECU, the bike started twice, dying quickly probably because its flooded from so many failed starting attempts. But it did start twice because repeating the previous problem.
Also, I’ve gotten it to run for 10-20 minutes 2 or 3 times. During that time I would rattle the wiring harness everywhere, trying to replicate the short. After a while it would blow the fuse again for no apparent reason.
I thought this might change things a little, especially in terms of the bike shorting the ECU.
I will let you know of my findings tomorrow. Thanks again for your help
*before repeating the previous problem
Henry
Again, thanks for you help. That was the problem and the bike has been running great (even better it seems) ever since.
Another common problem on the 05 636 is random shutting off after aggressive driving. At some point it will start bucking and shut off. Giving it a few minutes to cool down seems to fix the problem. A lot of people say its a faulty ECU and they say replacing it fixes the problem. I did manage to run into the problem the first day I got the bike running again. Have you heard anything about this? Do you know if it can be anything except the ECU? Let me know
Thanks
I am having the same problem with it bucking and shuting off.I have heard of changing the ecu but i’m not sure.Does switching the ecu fix it for good or will it happen again.please let me know