2006 GSXR 600 Crank but wont start. Fuel pump? RR / Stator? SOLVED!!

3901 Views 10 Replies 2 Participants Last post by craigfer63, Jul 1, 2021

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Discussion Starter · Jun 17, 2021

Hi guys, new to the forum here. Seems like an active forum so I thought id post here to see if i can find some answers.

Anyway, I've replaced the original stator & rectifier a few years ago with ricks motorsports bought brand new and rode for at least 1000 miles. The bike started up and ran fine until one day she died on me. Check the connectors for the rectifier/stator both plastic connectors were burnt. I used wire nuts to connect to the oem connectors(old ones) Since then the bike have been sitting for at least a year. All the fuses and including the fuse on the relay is good. Bought a new battery recently and tried to the start but it didn't want to start. I sprayed some carb cleaner into the throttle bottle to see if it would fire and it did for a second while revving the throttle. I'm thinking it can be the fuel pump out being rusted? Is it possible that the rectifier / stator went bad when the connectors melt? If anyone has any input please let me know. what the issue could be. Check the youtube link to see a video of my bike.

Thanks in advance. RIDE SAFE

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craigfer63

· #2 · Jun 17, 2021

Lots of threads on here about your exact problem. Google will show more posts here.
Service Manual goes through each system step by step.
OEM Stator and RR are the best parts to use and have been upgraded over the years.

2006 Suzuki GSX-R600 OEM Parts, Ron Ayers

Shop our large selection of 2006 Suzuki GSX-R600 OEM Parts, original equipment manufacturer parts and more online or call at 252-758-3084

www.ronayers.com

Burnt wires mean new RR and or Stator.
SUZUKI GSX-R750 SERVICE MANUAL Pdf Download | ManualsLib

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617K6

Discussion Starter · #3 · Jun 17, 2021

craigfer63 said:
Lots of threads on here about your exact problem. Google will show more posts here.
Service Manual goes through each system step by step.
OEM Stator and RR are the best parts to use and have been upgraded over the years.

2006 Suzuki GSX-R600 OEM Parts, Ron Ayers

Shop our large selection of 2006 Suzuki GSX-R600 OEM Parts, original equipment manufacturer parts and more online or call at 252-758-3084

www.ronayers.com

Burnt wires mean new RR and or Stator.
SUZUKI GSX-R750 SERVICE MANUAL Pdf Download | ManualsLib

Thanks for your input. Will definitely order some new ones soon.

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Discussion Starter · #4 · Jun 30, 2021

Here’s a follow up so I replaced the stator and rr and bike still won’t start- I’m going to take out the fuel injectors and spark plugs for cleaning. Hopefully that helps. New battery, new stator, new rectifier, cleaned fuel pump assembly yet the bike isn’t turning over. Any help is appreciated!! Thanks

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craigfer63

· #5 · Jun 30, 2021 (Edited)

I'm sorry if I led you astray with the "new Stator and RR". These are spare parts now.
Burnt wires are a big problem, the bike can burn down. At least you found this.

I did say the service manual will lead you through these systems, step by step. This is a process of elimination and you have eliminated these items, but "throwing money at a problem" is random and more luck than elimination.
I watched your YouTube Vid again ! Your Fuel Pump is not priming when you turn the key on !!! I'm going deaf in my old age. It does sound like there is no fuel and as you said it does start with fuel sprayed in the intake.
"Bike sitting for a year" What does the fuel tank look like ? And is there any fuel in it ?

Go to Fuel Pump in the manual and try those steps.

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Discussion Starter · #6 · Jul 1, 2021

This bike has been a money pit. Anyway the tank itself was a little rusty, I cleaned it out and added new fuel. I think the fuel pump is priming, when I unplug the gas line from underneath the tank, gas is shooting out from the connector that's attached to the tank, this happens when I turn the key to the on position while pressing the red killswitch . The fuel injectors checks out good, all are firing. I checked all fuses including the main 30A fuse that's connected to the switch relay. I'm not sure what else it could possibly be. Going to check out the spark plugs/ fuel coils next. Thanks for the help @craigfer63

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craigfer63

· #7 · Jul 1, 2021

The Workshop Manual has a fuel flow test. I listened carefully to your vid and I think I heard the fuel pump prime.
Now looking at the dash I see you have an FI on the screen. You need to put it into Dealer Mode to get the C code.
A good thread here.

Steve's GSXR pages - Dealer Mode

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Discussion Starter · #8 · Jul 1, 2021

Problem solved!! Replaced my spark plugs and bike started right up. Thanks for the helps/views 😅

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Discussion Starter · #9 · Jul 1, 2021

craigfer63 said:
The Workshop Manual has a fuel flow test. I listened carefully to your vid and I think I heard the fuel pump prime.
Now looking at the dash I see you have an FI on the screen. You need to put it into Dealer Mode to get the C code.
A good thread here.

Steve's GSXR pages - Dealer Mode

Thanks! FI light came on because my intake was unplugged

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Discussion Starter · #10 · Jul 1, 2021

GSXR-600 start up. New Spark Plugs, Rectifier, Stator, Cleaned Fuel Pump, Cleaned injectors. K6

youtube.com

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craigfer63

· #11 · Jul 1, 2021

Very good, always good to hear her fire up !
To follow up on your problem, what did the old spark plugs look like ? I am surprised that the spark plugs were the problem with this issue ?
Unless all four had no spark (no continuity/resistance through the electrode) Then the problem may have been something else you worked on.
Now you are much moor familiar with all the systems on your bike.

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