2006 ZX6R Won't Start - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 15 (permalink) Old 03-23-2010, 02:03 AM Thread Starter
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2006 ZX6R Won't Start

Hey all,
So got a bit of a situation with my bike, and I am hoping I can get some help.
I was out riding yesterday, and loving life. I refueled my bike, as the fuel light had come on, and went for a ride with a buddy. As we were riding, he noticed my brake fluid reservoir was loose, so we pulled off, and I fixed it. I had shut the bike off to do it, and when I went to restart it it gave me some problems...It was trying to turn over, but wouldn't bite right away...seemed like no fuel was getting to the motor. After cranking it a bit, it fired up, and ran with no problems...we went for about 1/2 hour and stopped for lunch, then got back on our bikes and rode for another 40 minutes or so (no issues starting the second time so I assumed there was a small gap when no fuel was in the line when it initially wouldn't start earlier).
When we stopped the third time, we were off our bikes for about 1/2 hour again, and when I went to start it, again no dice...no matter how many times I tried to start it, no luck...we tried push starting it, and got a small cough, but no actual start.
I pulled it into the garage at work, figuring I would pull the plugs and see if that was the issue. They were definitely fouled, so I changed them out. No start. I did check to see if I was getting spark, and there was.
I also made sure to put the bike onto a trickle charger to make sure the battery was charged, which it was...to ensure the battery wasn`t shot, I also tried jumping the bike with my car (not running) which was one of the suggestions I got from a mechanic at my bike shop. Again, no start.
I've also done an oil change and an oil filter change (neither of which I think are problems but figured I might as well do them while the bike was in pieces).
The FI light does come on when I initially turn the key, but goes off once the start up sequence finishes. The low fuel light stays on, and the word "fuel" comes on under the tach...(there is plenty of fuel in the bike so I know I haven't run out of fuel).
One other thing to note...I did notice what I think is the overflow hose from the tank seemed kinked...could that cause a non-start problem?
History of the Bike:
I bought the bike last August, from a guy who lost his license and hadn`t ridden in a few months...not sure how long the fuel sat in it. Bike had 3500km on it. I rode until October, replacing a battery after the one that came with the bike crapped out. The bike was stored in a heated underground garage for winter, and the fuel sat in the tank until February, and (my bad) no fuel stabilizer was added. The bike has run well for the first few rides, with this being the first issue I have had. This February, I added a trickle charger to the battery so I wouldn't have to keep pulling the tank off to get at the battery.
I don`t know a ton about bikes, so I won`t pretend to know what`s going on..I have looked at the fixes I can accomplish with my basic knowledge level...
I am thinking that no fuel is getting to the plugs, but I am not sure why..I am wondering if either the fuel pump is shot, or the filter is plugged with crap, and that`s what is stopping the bike from starting. Unfortunately, I can't even find a fuel filter (although I did pull the pump off the tank, thinking it might be attached....there wasn't one I could see).
Any advice people can offer would be great!

2006 ZX6R 636 in Kawi Green!!!
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post #2 of 15 (permalink) Old 03-23-2010, 07:17 AM
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Can you hear the fuel pump when you turn the key on?
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post #3 of 15 (permalink) Old 03-23-2010, 08:04 AM
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Sounds like the fuel pump may be shot. If it's cranking it's not the safety switches I would change out the fuel pump. But make sure no hoses are kinked or disconnected or plugged.

Anyway my 2 cents!

2006 Lime Green ZX6R
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post #4 of 15 (permalink) Old 03-23-2010, 08:05 AM
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Sounds like bad gas to me.
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post #5 of 15 (permalink) Old 03-23-2010, 08:06 AM
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my guess is that your fuel filter is clogged. b) the fuel level sensor is dead and somehow hinders the fuel transport (not sure whether this makes sense) c) fuel pump is dead or just the fuel line got loose from the pump...
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post #6 of 15 (permalink) Old 03-23-2010, 05:21 PM
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it's cranking. we can rule out clutch switch, neutral switch, sidestand switch

you're getting spark. so we can rule out crank position, cam position sensors

what we don't know is if you're getting fuel. prop the tank up, remove the fuel line coming from the tank and place another length of hose on the fuel pump. insert it in a bucket and turn on the key. if it pumps fuel into the tank your pump is working, but still might not be providing enough pressure for the injectors to properly function, or your fuel pressure regulator could be bad.

if the pump doesn't work it could be a bad pump, or fuel pump relay or wiring to the pump, or a clogged fuel filter. the lever sender has nothing to do with fuel delivery so that's not it.

you could also have bad wiring to the injectors. since it is highly unlikely for all the injectors to fail at the same time.

since you just fueled the bike before the problems started, you could also be looking at contaminated fuel.

if the fuel line had become disconnected you would have known it immediately as there would have been a huge puddle of fuel on the ground when you tried to start the bike.

you mentioned the tank vent hose was pinched. this can prevent the bike from running. to check if this is the cause, open the fuel cap and try to start the bike. if it starts that was probably it.

if all other possible options check out, the only thing left is the ecu.

2005 ZX-10R Street and Track Whore

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post #7 of 15 (permalink) Old 04-05-2010, 08:30 PM
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I'm having the same issue with a friend's 636. I took out the fuel pump assembly yesterday and tested it the way it was mentioned here. I noticed gas was pumped out but it didnt seem very strong... seemed more like it just let gas out instead of actually pumping it. How strong is the flow supposed to be?

We tried to pop the clutch... bike just growled and didn't respond to my throttle twists.

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post #8 of 15 (permalink) Old 04-22-2010, 01:59 AM
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i am not an expert of motor byke...but i want to say some thing
if you hear the fuel pump when you turn the key on....the problem is there
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post #9 of 15 (permalink) Old 04-22-2010, 02:04 AM
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review my no start thread on the 05-06 forums try my methods...

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post #10 of 15 (permalink) Old 04-22-2010, 02:20 AM
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Originally Posted by george.mikal View Post
i am not an expert of motor byke...but i want to say some thing
if you hear the fuel pump when you turn the key on....the problem is there
nice bump, noob. i dunno if it's the language barrier but you DO want to hear the fuel pump prime.

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