2004 ZX10 Won't Start - Kawasaki ZX-10R.net
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post #1 of 41 Old 02-23-2010, 01:12 PM Thread Starter
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2004 ZX10 Won't Start

Hello all! I just recently got my ZX10 and love it!

I have recently been having a problem with it though. The day after I got it, it gave me a trouble starting. It would crank over fine but wouldn't start and the FI light came on. I turned the key off let it sit for a second and tried starting it again and it started up instantly with no FI light. I figured it was just a fluke.

Now (a few weeks later), the bike is doing the same thing but won't start at all and the FI light flashes if you crank it over. I have traced it to code 23, which is the cam position sensor. Now why there is a cam position sensor, and a crank position sensor on a machine without VCT is beyond me but the problem remains. I have checked all of the wiring and all of the plugs/connections look perfectly fine. I tried pulling the battery lead off to 'clear' the code and it is still there as soon as you turn the key to ignition.

The local Kawasaki dealership is an honest business and they don't scam people. They quoted me $200 for the sensor and install if it is in fact just the sensor but I'd like to try to avoid the $200 bill if I can.

Is this a common problem with these bikes? I have heard of the alternator problems but I'm hoping that there is something simple to look for here. Any tips or suggestions on how to fix this?
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post #2 of 41 Old 02-24-2010, 08:34 AM Thread Starter
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I've ordered a used sensor to see if plugging that one in will make the FI light go away at ignition.
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post #3 of 41 Old 02-25-2010, 02:42 AM
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Quote:
Originally Posted by anaxagoras1986 View Post
I've ordered a used sensor to see if plugging that one in will make the FI light go away at ignition.
There is no other solution.
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post #4 of 41 Old 02-25-2010, 03:55 AM
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There is no other solution.

BURNOUT.....
Attitudes are contagious. Mine might kill you.
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post #5 of 41 Old 02-25-2010, 08:28 AM Thread Starter
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Thanks guys!

Does the ZX10 do a self test at ignition before you start it? I'm assuming that if the sensor is shot, perhaps it can tell by continuity? I wonder if, as a test, I could just plug the electrical plug in (and ground the housing)for the new sensor and see if the light goes away at ignition. What do you think?
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post #6 of 41 Old 02-25-2010, 11:39 AM
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You cannot bypass the cam sensor, It's needed when the ecu calculates the rpms, you will possibly destroy your engine. Not worth the risk imo...Just wait for the part.
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post #7 of 41 Old 02-25-2010, 03:28 PM
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Did you check the pins going to the cam position sensor connector. I've found those to be culprit majority of the time.
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post #8 of 41 Old 02-25-2010, 03:48 PM Thread Starter
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Tasos- I didn't say anything about starting it without the sensor. I was asking about if the ECU does a self-test at ignition BEFORE startup. It complains about the sensor before cranking which leads me to believe that it does some sort of a self-test. Or does it just remember an issue and complain until it sees the issue is gone when it is running?

Why does the bike have a cam position sensor and a crank position sensor?


I've reseated the connection on the sensor loom, a large connector behind the left engine mount, and the connections on the ECU. They look like they are in good shape too. Are there any other ones?

Thanks again for the suggestions guys!
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post #9 of 41 Old 02-25-2010, 03:58 PM
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The connector sits on top of the valve cover on the right side smog plate. I've seen a lot of people pull the pins out of that connector when trying to remove that connector to pull the valve cover. Look at that connector.
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post #10 of 41 Old 02-26-2010, 01:13 AM
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Yes it does a self test on all sensors everytime you turn the switch. When the sensor is fixed the FI light will go off and the bike will start.

It uses the sensors to calculate the rpms so it knows where to engage the rpm limiter.

Are you from around my place?
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