06 Daytona 675 race bike.
Very early in the race weekend the bike became very difficult/impossible to start with the starter. To get it going I had to roll start it and thumb the starter at the same time. I even tried an extra earth lead between the main earth and the frame (as suggested by a few mechanics at the track).
In the end, everything came to a head when the bike died under power down the straight - the dash went blank and the bike just died.
Back in the pits I discovered the 10A ignition fuse was blown and subsequent replacements also blew until I used a 15A unit, however it would still not start (even rolling it like before).
Along with the fuse issue, I also noted the gear indicator did not change from zero and the neutral light would not illuminate, regardless which gear was selected.
Previously this season, I've had issues with the bike cutting out momentarily when under throttle. It was like the quickshifter sensor was vibrating and cutting the spark. Oddly enough, it was far more prevalent when the bike had more fuel than just above where the low level light comes on.
To fix this issue, I pulled the HM quickshifter, changed the internal pump and filter in the fuel pump (new Kemso unit) and also fixed a broken intake temp sensor plug while I was there.
Battery is a 2y.o. SSB unit that lives on a tender between race meetings (and in the pits between races).
Plugs are iridium - pic included.
Currently running a toggle switch rather than the OEM keyed ignition.
Tank pump and fuel level sender plugs have been replaced from a donor loom. As well as the air intake temp sensor plug. Crank position sensor was also been replaced a while ago with a cheap Chinese one.
The bike has always been temperamental to start when very hot. An auto elec explained to me that as the starter motor gets hot, more current is required to start the bike due to heat soak.
How can I test the gear position sensor?
Would it prevent the bike from starting?
Any other ideas?
Obviously I'll look the loom over for any damaged wires or potential earths.
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