i need some help. i powdercoated my frame and subframe, put everything back together, and now my bike is not starting. it cranks and cranks, but wont turn over. i pulled the spark plugs and checked for spark...no spark. i changed out my ecm, changed the battery, checked the ground cables(because of the powdercoat may have gotten in the way for proper ground), and checked the ignition pulse generator. everything seems fine. any ideas of what could be the problem? all the lights work, the fuel pump is working, there is just no spark...i'm at a "troubleshooting block" right now, and i dont know what to do. any ideas?

 

My first suggestion would have been to clean off any mounting surfaces. On some designs, those mounting surfaces act as grounds and the powercoat will not allow the ground to take place. I know you did the wires, but any mounting surface may be doubled as a ground.

My guess is the engine is not grounded. check to see if you have a proper ground to the engine. I would take a jumper wire from your negative battery terminal, wrap it around the spark plug and turn it over. If it sparks there, you have an engine ground issue.

If you have a multi-meter, start running around looking for grounds that should be grounded. Anything that is touching the frame will be grounded. Even something like a bracket may need to be grounded.

The other thing that wasnt mentioned is how far back together is the bike? If you don't have the gauge cluster plugged in, it may not fire. Also, if your Bank Angle Sensor is not plugged in, or not right side up, it won't fire or kick on the fuel pump. Im not sure where its located on your bike, most of the newer bikes have them behind the headlight, but I think yours might be under the seat.

 

thanks for the response. i did scrape the powdercoat off of the frame where the ground would be touching, but ill check it again...also there is a resistor that screws in the subframe that has powdercoat...so ill check that as well.

 

the bank angle sensor is fine as well as the gauge cluster. everything is back on the bike except for the fairings. i tried the thing with the battery and the spark plug, but still no spark. im not sure if i did it right tho. i pulled one of the spark plugs, connected the end that the boot goes over to a jumper cable, and put the other end of the jumper cable on the negative terminal of the battery, turned it on and cranked it. no spark. this is getting very frustrating. please if anyone has any idea on what could be the problem? how do you check and see if the ignition pulse generator is messed up? i dont see why it would be, but i couldve sworn the fault code flashed 19 once. also, i had both crankcase covers (the stator and the oil side) both powdercoated, but i put the stator in a ziplock back so it wouldnt get all dried out being exposed to air. i hope this all makes sense.

 

for the sparkplug, I meant to plug the sparkplug into the boot, then take the jumper ground wire and ground out the plug. You can do this by attaching the jumper wire to anywere on the metal portion of the plug, such as the threads. just wrap the ground wire around it.

Did you remove the Pulse Generator from the cover before powdercoat? I know you said you removed the stator, but didnt say wether or not you removed the pulse generator. If not, the electric charge of the powdercoat process could have damaged it. If it was bumped, it may have damaged it as well. Be sure the mounting surface of the cover is clean form powdercoat.

According to my bikes manual, (05 1000RR), the peak voltage should be a minium .7 V while the engine is cranking over. Im sure its close to the same for your bike.

The stator should have nothing to do with it. So even if the stator somehow got messed up, it would still start.

Also, does your fuel pump prime when turn on your key? If not, the spark and fuel pump are more than likely related. You should be able to hear pump prime as soon as you turn on the key.

 

ok so i did the sparkplug thing again...and no spark..so im going to try a brand new spark plug, jsut in case they all 4 fouled out...lol...i did remove the pulse generator from the crankcase...and i hear these things are pretty tough, so i dont think its that...its not like i took it out and beat it with a hammer...but im open to all options at this point. how would i be able to tell if its bad? i checked it the other day, it seemed fine...i even tried taking off the little flywheel that it reads but couldnt get the bolt out of the center of it so i just left it alone...the fuel pump turns on when the key is turned on...everything operates normally, except that it wont fire. i dont see why the spark plugs wouldve fouled out, but thats pretty much the only thing i havent tried yet.

 

i think its probably the ignition pulse generator. is there anything i should know before installing it? or just unscrew the old one and put this one in?

 

should just be a plug it in and go. But as with any sensor, you should probably unhook your battery before you swap em out.