2002 R6 no start after transmission repair
I just wanted to put up a thread to let some people know about the problem I have been having with my bike for the past year. It was a stupid mistake on my part, but it took me out of riding for a year which was frustrating, and hopefully it can be of use to someone with a no start.
I originally picked up the R6 for $1600, knowing it as a second gear slip. Over the following winter, I tore the bike down and replaced my transmission with the upgraded on from the 03-05 R6. The bike ran awesome, no more slip!
A couple weeks later, the bike died on me 2km from home. After working on it off and on for a couple weeks, I realized I had forgotten to tighten down the ground cable on top of the engine block (like an idiot). After repairing that, the bike ran great again.
Another couple weeks later, the bike quit on my way home from work. I traced that to a no spark issue, which I could not resolve. I tested all of the electrical systems in the bike, (main switch, ignition switch, clutch switch, neutral switch, kill switch, Starting Circuit Cutoff Relay, ignition fuse, main fuse), I took it to my local dealership and had them take a look in case I missed something.
After a month, I called the dealer for an update. They told me that they couldn't find an issue either, and told me that I should find a ICU to put in it and see if it worked. After spending a few weeks and $200 on an ICU, the bike still would not start. I then decided to take the bike back from the dealership, and finish working on it on my spare time.
I decided to start my own diagnosis by hooking up a multimeter to the pickup coil and seeing if I could read the voltage change while cranking. The meter read a .05 mV change. I then took the pickup coilbcover off to see if there was something wrong with the pickup coil visually (as it tested good according the service manual).
When I pulled the cover off for the pickup coil, I couldn't initially see anything wrong. So, as a hunch, I turned the bike over while watching the pickup rotor to confirm it was turning. When I cranked the engine over, the rotor wouldn't move. The bike that held it to the crank had come loose, and the rotor was just spinning freely as the crank turned, so the ICU never saw a crank signal to fire the coils.
Long story short, I have learned two things from this process.
1. Don't over complicate. The specs won't lie to you. If everything tests good, then start looking elsewhere. Don't look for what you think the problem is, look for the actual problem.
2. Make sure your flippin bolts are tight!! 😂. I missed out on a lot of riding over the past year and a half, over a ground screw and pick up rotor bolt. It never hurts to double or triple check stuff.
I hope this long story will help someone else with a no start issue.