Electrical problems. Help!!!

[RustyGubbins]

Hi all,


Was hoping that one of you experts could give me a some help/advice...?


I am having trouble with my charging system. The LCD displays is showing error code '46', which as I understand means that there is an error with the charging system.


As I am not the best person when it come to electrical knowledge, I bypassed the multimeter method of checking voltages, etc, and I bought myself a new battery mainly because I had left it on charge for a lengthy period and I thought I'd ruined the last one. I placed the new battery in the bike and got the same issue.


Following this, I bought a new regulator/rectifier. Tried that - same issue.


So then I thought that my stator/generator may have gone. So I removed that, but tbh it looks fine. There are scorched areas, and no areas that look particularly burned.


I am now wondering if I should get another stator/generator, or if the issue is something else. It can't really be anything else, can it? The system is pretty simple in terms of components. Perhaps a wiring issue? I am wondering whether I should put it all back together again and give it a try again. But I don't want to end up miles from home with the engine unable to start (again).


I have attached pics of the stator in it's current state. I have shown both sides. See what you think...


Also, does anyone know where I can get an FZ6 stator for a 53 plate (2004) FZ6? The internet is having trouble finding them. Are there any that are cross compatible with other bikes, that are easily obtainable?


Please help!


Stator pics attached.

[RustyGubbins]

Anyone think the stator looks fried? 

[slappy]

Anyone think the stator looks fried? 

Looks more like lightly grilled to me
 
I think error 46 is battery related, make sure the new battery is fully charged and all connections are clean and tight.

[RustyGubbins]

Slappy,


Looks lightly grilled 


I have done what you suggested. No joy.


May try again tomorrow. I have the day off. 

[Fazerider]

The generator doesn't look obviously bad. A resistance measurement between each of the white wires may tell you something, but some faults can fool that check.
The best test is simply to measure the battery voltage, if it's around 13.5v when the engine's idling and around 14.5v when revving a bit faster (with headlight on) then it's fair to assume that the charging side is OK.
If that is the case then the problem may be a poor connection to the ecu or instrument panel causing it to report a charging issue when there isn't one.

[RustyGubbins]

Thanks Fazerider.

May have to go get myself a multimeter then. :/

I'll give it a try.

[Grahamm]

From this page:

Fault Code: 46
Diagnostic Code: --
Symptom: Power supply to the FI system is not normal.
Probable cause of malfunction:
Malfunction in "CHARGING SYSTEM".

I'd definitely recommend getting a multimeter and checking the connections in the Fuel Injection system to make sure there's good continuity and no shorts etc.

Also check the output from the Stator and Regulator Rectifier.

[unfazed]

The error code can be a little confusing and as it really mean that the voltage levels to the Fuel Injectors is less than it expects/requires to function properly.
While this could be a faulty charging system or a dodgy battery or Rectifier/Regulator it could also mean that the the connectors to the injectors could be corroded causing a high resistance thus giving the wrong voltage levels to the injectors and/or the ECU.

As Grahamm says check the injector connectors, but not just the injector connectors but the ones to the ECU and coils also.
I find a spray of WD40 will do no arm and help keep corrosion at bay.

Then do a charging check  by putting a volt meter across the battery terminals with the meter set to DC voltage above the 20 Volt range if it is not auto switching. Start the bike and rev the engine the voltage should rise to a max of about 14.4 volts at around the 5000 rev mark
If you light are off switch the on the meter will drop and should start to rise again. Try the same test when the motor is at full temperature to test if the insulation is not breaking down when hot.

The generator looks ok, but looks will not always show a dodgy connection or low insulation.

[RustyGubbins]

Thanks Guys.

I bought a multi-meter and checked my voltage at the battery terminals. All seems fine to me, but then I am no expert.

I have someone who is going to look at it for me this week.

Fingers crossed! Need to get out on it before the sunshine disappears!!!

[unfazed]

Did you do the suggested tests and check all the connections?

[RustyGubbins]

Hi, yes.

Turns out that it was the regulator/rectifier.

I had bought a new one as that what what I suspected needed replacing, but the new one I bought was also defective!!!! Not happy.

All sorted now.

Cheers for the advice!!

[Grahamm]

Turns out that it was the regulator/rectifier.

You might like to visit a friendly garage and get them to put a Load Tester on your battery.

My R/R died a while back and it killed one of the cells on the battery making the bike difficult to start (eventually I had to resort to bump starting it!) until I got a replacement R/R and battery.

[RustyGubbins]

Will do. Cheers Grahamm.

[helmetvonthrob]

My FZ6 had been showing signs of an occasional misfire and generally being a bit flat.


I left it without starting outside for about 6 days, the battery went flat so i thought I'd pull it out and charge it, no joy, so had to get another one.


Now, when I hit the starter, the engine spins over sooo much faster and the lumpiness/flat spots appear to be gone!