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Discussion Starter #1
I have a 2004 ZX10R with about 25k miles on the clock. Tonight while out riding on the highway (5th gear, ~75mph) the bike fell flat on its face and the oil light came on. I feared the worse seeing that light and the abrupt deceleration. I let it sit for a sec while I visually inspected the bike. Didnt see any oil leaks, started it back up, and it fired right away. I let it idle for about 1 minute and revved it a bit just to be sure, and it kept running. I hopped back on it and exited and roughly 200yds later it died again (2nd gear, ~20mph). This time I pulled over, and tried to restart it (about 10 sec after it died) and it fired right up again. Got back on the road and headed out. About another 1/4 mile down the road it happened again. So I started to pull over, gave it about 5 sec and it started fine. That was the last time it happened. All this time the engine temp was between 190-210 so it wasnt overheating. There is plenty of gas in the bike as well.

The only thing that comes to mind is I washed the bike today so hopefully its just some water got in somewhere. But that doesnt seem likely since I was riding for about 40 min before this happened and no problems all that time. The bike isnt running rough at all or hesitating. It is honestly running perfect up until when it dies, and it is very abrupt.

Engine mods on the bike:
Akra CF slipon
KN filter
PC III USB

I looked all around the bike and didnt see anything wrong with it visually. Could a PC III go bad and cause this issue? Is there a diagnostic you can run on it when hooking it up to the computer?

What it feels like when it dies: Hitting the kill switch
 

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Discussion Starter #2
Oh and to add on to that, I CANNOT POP THE CLUTCH. If it dies and I pull in the clutch and then dump it back out, it wont start itself back up. I HAVE to hit the starter switch to get it going again.
 

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just a thought ... could it have something to do with the kick stand switch. Sounds like its thinking the stand is down when its not. Good luck, I hate electrical problems.
 

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The clutch switch wouldn't be an issue. I haven't had one plugged in since I got my CRG GP Clutch perch (there is no provsion for the switch on the Perch). Kickstand switch could be the culprit but it would be continuous. I would need more details. Any surging? Does it slowly die (RPM's drop even though you twist the throttle)? Is it a sudden power complete out and engine completely dead? A bad or going bad PCIII could cause symptoms like that but ride it some more and if the problem persists worry if not forget about it.
 

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Do you have a FI light on? Can you read a code off it?

I had an intermittent like that where the engine would stall. The fan had worn it's way into the camshaft position sensor lead and as soon as the engine warmed up, the fan would come on and break the connection, causing a FI error.
 

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Discussion Starter #9
The clutch switch wouldn't be an issue. I haven't had one plugged in since I got my CRG GP Clutch perch (there is no provsion for the switch on the Perch). Kickstand switch could be the culprit but it would be continuous. I would need more details. Any surging? Does it slowly die (RPM's drop even though you twist the throttle)? Is it a sudden power complete out and engine completely dead? A bad or going bad PCIII could cause symptoms like that but ride it some more and if the problem persists worry if not forget about it.

Engine runs perfect and instantly dies as if I hit the kill switch. It will not re-start till I hit the starter (popping the clutch does nothing)
 

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:hello::hello::hello:DO NOT WORRY!!!04'don't die that easy..!!it seems to me that this is a minor electrical or electronic problem..so a few ideas..
1.i faced a same problem suddenly to my 04',no FI indication,and after checkin' many things,(from fuel pump to sensors)the problem lied to PCIII.I just made a reset (it takes only a few seconds with your pc)and 3 years now no problem again.take in mind that teh English magazine SUPERBIKE,faced the same problem to their 04'longtermer.

2.try to disengage the clutch sensor(for not leaving with sidestand down).5 kawis of mine to the past faced the same problem,happening any time and confused me for long periods before finding the solution..it's also well known problem to kawi mechanics.SO,good luck....,and let us informed,what finally the problem was..!:cool:
 

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:hello::hello::hello:DO NOT WORRY!!!04'don't die that easy..!!it seems to me that this is a minor electrical or electronic problem..so a few ideas..
1.i faced a same problem suddenly to my 04',no FI indication,and after checkin' many things,(from fuel pump to sensors)the problem lied to PCIII.I just made a reset (it takes only a few seconds with your pc)and 3 years now no problem again.take in mind that teh English magazine SUPERBIKE,faced the same problem to their 04'longtermer.

2.try to disengage the clutch sensor(for not leaving with sidestand down).5 kawis of mine to the past faced the same problem,happening any time and confused me for long periods before finding the solution..it's also well known problem to kawi mechanics.SO,good luck....,and let us informed,what finally the problem was..!:cool:
:+1: If you have a PCIII there could be your issue.

Also try a loose battery cable that might be your culprit.
 

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Discussion Starter #12
:+1: If you have a PCIII there could be your issue.

Also try a loose battery cable that might be your culprit.
I can almost narrow it down definitively to the PC III. Its cutting off the fuel but I dont know why. I reset it already, but that hasnt resolved the issue. I checked the ground for the PC III and its in good order. I guess next is to pull the tank and check the ECU connector?
 

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Check the connector but I doubt it. Those connectors are a b*tch to get off so for them to come undone unlikely. Maybe a pinched wire or something of that nature. If none of that is it the PCIII might have internal failure. Also the tip over sensor could be faulty. That would cause the bike to completely die.
 

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Discussion Starter #14
Check the connector but I doubt it. Those connectors are a b*tch to get off so for them to come undone unlikely. Maybe a pinched wire or something of that nature. If none of that is it the PCIII might have internal failure. Also the tip over sensor could be faulty. That would cause the bike to completely die.
Never thought of the tip over sensor. It seems to happen mostly when I hit a bump. Is there a way to bypass it? Also, will the bike run w/o the PCIII connected?
 

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I really wish I could offer some help on this issue. I just moved to the '08 from the '04 and feel your pain, very interested in what is ultimately uncovered.

I forwarded the link on to a mechanic friend of mine to see if he could help you out.

Keep posting !
 

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Discussion Starter #16
I really wish I could offer some help on this issue. I just moved to the '08 from the '04 and feel your pain, very interested in what is ultimately uncovered.

I forwarded the link on to a mechanic friend of mine to see if he could help you out.

Keep posting !
Well strangely enough, I fixed it last night. Some water might have made it into the ECU connector. I blew it out w/ compressed air and pushed it together. When I took it out for a spin again (20min) it didnt happen. Ill go for a longer ride in about a week to see if it happens again.
 

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sounds like a bad connection to the battery..had the same issue with mine turned out the screw on the battery terminal had come loose from all the vibration
 
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