2004 R6 electrical /cutting out problem???

[Ryan676]

Hello All mechanics and know-hows..
I have been around bikes for some time and wrenched on everything with an engine.Unfortunatly I can not diagnosis this R6 problem. I have had it to 2 shops already and no results.
Here is the problem: I had no problems beginning of the season. It started out mildly during a WERA event @ Nelson Ledges. My first 2 races no problem, then the last race of the day it got compounded and I finished last place from a 6th start lead.
At around 9500-10000 RPM the bike shuts down and will not climb on power almost like you were on the rev limiter. Then it will surge up to 14000 rpm and then not pull at all past that and is real erradic in power delivery.
The motor has been inspected pre-season. Compression, leakdown, valve adj, and cam timing all in spec.
New fuel pump added and fuel pressure and injectors tested. A-OK there..
Power commander, ECU, and all relays switched out but still occurred on the Dyno the same results.
Coils were also tested and show no problem there. Dash and gauges were swapped out as well.
the bike starts and idles and will climb to the rev limiter on the stand. Not under load thou?
The shop told me that it must be the wiring harness since the wire must be broke somewhere inside ??/
I put a new harness in as well and same problem occurs
Fuel filter and lines are clean.

I am about to swap out the pick up sensor and the rectifer as well to see if there is any problem with those.. I am running out of electrical components to test and replace and now need some input from others.

Does anyone have any suggestions or ran into this problem before???
All help is appreciated.

Thanks

[cardzilla]

Sounds like one of those dreaded R1 / R6 gremlins.  Here's a link to a sticky on the R1 site, maybe you can take something from it that can help... good luck.

http://www.r1-forum.com/forums/showthread.php?s=&threadid=98831

[DAmico]

It's your throttle position sensor. It's a very common yamaha problem. I actually just had a GSXR 1000 that had the same problem. It will not show up as a code, but will cause running problems, obviously. The yamaha part# is 5SL-85885-00-00 and the ronayers.com price is $74.01

[mdr14]

If it is the TP sensor, you will be able to see any discrepency in real time while on the dyno with the power commander software running... or at least we are able to with the suzuki's when they have TP problems

[K3 Chris Onwiler]

We had a very similar problem on a first generation R6.  Not saying this is it, but worth a try.  You're running a racing style billit hard cover over your ignition, right?  Check the ignition pickup wires where they go through the rubber grommet into the hard cover, and all the way down from there to the pickup.  We found a short in that wire, and fixed it with solder and tape.  That bike still gets raced, and it's been fine for a few years now.

[Ryan676]

Thank you to all that have replied. I bought and installed a new TPS and I still have the problem. I am at a loss since 90 % of the electrical has been replaced and tested OK.. I am at a loss right now as I can not run any event competitively and have loss 1/2 of the race season on this 04 R6.. The shop bills are adding up since no one has been able to diagnosis it ... Sucks since I can not trace it out and find the problem.. All mechanical systems have tested OK as well..???
Other suggestions helpful as well..
Thanks

[cardzilla]

Ryan, I feel your pain man.  I had the same experience with my R1 last week and similar results when changing things.  I had a friend with an 03 R1 that ended  up changing the entire wire harness to fix his problem.  I've changed everything but the TPS, however I'm leaning in one of two directions.  Like someone posted earlier I'm going to check the ignition pick up (I replaced a case cover right before the problem started) and after that I'm thinking motor internals.  Maybe a cam sensor, who knows.  I'm building a superbike motor so for me this is only a backup motor which gives me time to figure it out.  When I originally posted with the link to the R1 forum I'd never had a problem, I guess I jinxed myself.

[Super Dave]

Try taking off the Power Commander.

[bluedevil]

I had a similar prob on my 03... But the display tossed a code on it.. Code 11 for me which was the Cam Position Sensor. I replaced it and problem was gone. Usually if its electrical or sensor related the R6 will throw a code on the display.....   ALso the bike will run fine on a stand but under load will fail.   The bike would be going along fine then cut out.  Bike stayed running but would not climb over 3500 ish RPM.    Also the problem was intermit.  I rode around the pit and all was fine.  Next race same thing.    Check that display carefully and see if a small code lights up...   Good luck resolving your issue.  Id say the throttle position sensor was not to far off of an idea either all though I would still think that would toss a code.....