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2006 GSX 600 SDI is dead, no dash lights, nothing


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#1 GSXLover

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Posted 12 January 2021 - 12:53 PM

Hi Folks, I'm new to this site and this is my first post but I've been riding sleds from all manufacturers since I was a teenager and I'm approaching 60 so I'm not a newbie. I have two GSX's, one an '04 and the other an '06. Both are 600 SDI's with electric start and ran fine last winter before I put them up for the season. This weekend, I hooked up the battery to each and the '04 fired right up. However, the '06 is completely dead. There's no clicking, beeping, dash lights or any sign of life when I press the start button. I've already checked the 30A fuse at the battery and all the fuses in the fuse box and they are good. I've also swapped the two relays in the fuse box with each other. I shorted the start relay near the battery and the starter engages and the motor turns over so I know the battery, which is reading 12.2V, has enough power to run the sled. I checked the input to the start relay near the battery and it does not read !2V when I press the start button. I've read some other posts and verified there is 12V at the F11 fuse. I've used the '04 sled for comparison and it's dash lights come on regardless if the kill switch is on or off so I don't think that is the problem. I'm wondering if it is the start switch at this point. Do you agree and, if so, how should I check it? What else should I check? Thanks in advance for any help you can offer!



#2 Mill

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Posted 12 January 2021 - 10:37 PM

Hi Folks, I'm new to this site and this is my first post but I've been riding sleds from all manufacturers since I was a teenager and I'm approaching 60 so I'm not a newbie. I have two GSX's, one an '04 and the other an '06. Both are 600 SDI's with electric start and ran fine last winter before I put them up for the season. This weekend, I hooked up the battery to each and the '04 fired right up. However, the '06 is completely dead. There's no clicking, beeping, dash lights or any sign of life when I press the start button. I've already checked the 30A fuse at the battery and all the fuses in the fuse box and they are good. I've also swapped the two relays in the fuse box with each other. I shorted the start relay near the battery and the starter engages and the motor turns over so I know the battery, which is reading 12.2V, has enough power to run the sled. I checked the input to the start relay near the battery and it does not read !2V when I press the start button. I've read some other posts and verified there is 12V at the F11 fuse. I've used the '04 sled for comparison and it's dash lights come on regardless if the kill switch is on or off so I don't think that is the problem. I'm wondering if it is the start switch at this point. Do you agree and, if so, how should I check it? What else should I check? Thanks in advance for any help you can offer!

I'd start with a properly charged battery then move down the line with a voltmeter.

12.2 volts = 50% dead.

These sdi's are very temperamental and like their batteries at full charge.

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#3 Daag44

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Posted 13 January 2021 - 01:25 AM

There would need to be a drastic drop in voltage for it not wake the gauges.
And if it were that low then it wouldn't turn over the engine like it does.
I am beginning to see why you are thinking the Start switch.
The switch is a common enough problem to be suspect.
 
Remove the 4 screws from the switch block to expose the two connectors.

 

Test for voltage on the Red/Brown wire using a volt meter or test light.
- If no voltage then there is no power from F11 fuse that needs to be fixed.

 

Press Start and test for voltage on the Beige wire.
- If no voltage or low voltage, then the switch is faulty.


Edited by Daag44, 13 January 2021 - 07:03 PM.

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Pictures - How to post with the correct orientation
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Pipe Pressure testing results from BRP
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Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
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Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
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Ski-Doo Snowmobile Tech Training
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Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix

#4 smurfy71

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Posted 13 January 2021 - 07:43 AM

- If no voltage then there is power from F11 fuse.
.


Hey Daag, I don’t mean to question, but this doesn’t sound right, is the “no” a typo?


Sent from the Island of Misfit Toys.
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2004 600HO SDI
2005 MXZ 500ss
94 MX 470

I have the 2004 service manual in pdf, ask for a link if you need it.
Nun replacement (service bulletin)


#5 GSXLover

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Posted 13 January 2021 - 02:08 PM

Last night I pulled apart the Start switch connector underneath the handlebars and did a continuity test on the three wires coming from the switch. I verified a normally closed connection between one pair when the switch is not pressed and a closed connection between a different pair when the switch is pressed. That pretty much matches the electrical schematic. Was planning to verify the wiring from that connector to the ECM next...a tougher job. Any suggested on how to do that? I"m assuming you need to remove the large connectors on the top of the ECM. I looked at them last night and didn't see an obvious way to unhook them. Any other thoughts assuming the Start switch is not the problem? Btw, I will swap the battery from the other sled that runs just to be sure it's not the problem. Thanks.



#6 Revs Up

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Posted 13 January 2021 - 06:08 PM

I know you said you checked the 30 amp fuse. Confirm the wiring and the fuse holder are good. Both are known issues.

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#7 Daag44

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Posted 13 January 2021 - 07:04 PM

Hey Daag, I don’t mean to question, but this doesn’t sound right, is the “no” a typo?


Sent from the Island of Misfit Toys.

 
Thank you catching the error and pointing it out. I have since made the correction. It still shows no voltage, but the conclusion is different.
 


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Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R P-TEK Electrical Troubleshooting #1 and #2 
800R Turbo
850 Center Oil line for coolant pump melted
850 Main Oil line caught fire #1 and #2
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's and Ronn's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Electrical - Diagnoses of a failed ECM
Electrical - 30A Battery Charging Fuse Socket Diagnoses and Relay
Electrical - Relay Coil Wine
Electrical - Relay Testing
Electrical - Battery Charging Relay Diagnostic 
Electrical - Troubleshooting with BRP video 
Electrical - Solder vs Crimp
Electrical - Diagram for Fanners on page 3
Engine Break-In 
Engine Weight 
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Electric Start troubleshooting
E-TEC Engine Management
E-TEC eRAVE position code recurring
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
E-TEC Voltage Rectifier Regulator troubleshooting
E-TEC Power Fades are not normal and can be fixed
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 Steering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Longevity - 800R E-TEC 
Mikuni o-ring for carb float assembly - Arctic Cat part# 6505-875 or from Amazon and eBay
Muffler Red Hot
Off-trail riding for flatlanders
Oil versus Fuel consumption
Pictures - How to resize and upload to DooTalk
Pictures - How to post with the correct orientation
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Power Loss - How to diagnose in the field
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Spark Plugs cracked
Squish - The limit
Squish - A discussion on head design
Stator and Relay Diagnostic 
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator Removal on page 3
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix

#8 Daag44

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Posted 13 January 2021 - 07:05 PM

I know you said you checked the 30 amp fuse. Confirm the wiring and the fuse holder are good. Both are known issues.

Sent from my SGH-I337M using Tapatalk

 
Exactly, and the easiest way is to test for voltage along the circuit..


Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R P-TEK Electrical Troubleshooting #1 and #2 
800R Turbo
850 Center Oil line for coolant pump melted
850 Main Oil line caught fire #1 and #2
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's and Ronn's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Electrical - Diagnoses of a failed ECM
Electrical - 30A Battery Charging Fuse Socket Diagnoses and Relay
Electrical - Relay Coil Wine
Electrical - Relay Testing
Electrical - Battery Charging Relay Diagnostic 
Electrical - Troubleshooting with BRP video 
Electrical - Solder vs Crimp
Electrical - Diagram for Fanners on page 3
Engine Break-In 
Engine Weight 
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Electric Start troubleshooting
E-TEC Engine Management
E-TEC eRAVE position code recurring
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
E-TEC Voltage Rectifier Regulator troubleshooting
E-TEC Power Fades are not normal and can be fixed
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 Steering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Longevity - 800R E-TEC 
Mikuni o-ring for carb float assembly - Arctic Cat part# 6505-875 or from Amazon and eBay
Muffler Red Hot
Off-trail riding for flatlanders
Oil versus Fuel consumption
Pictures - How to resize and upload to DooTalk
Pictures - How to post with the correct orientation
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Power Loss - How to diagnose in the field
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Spark Plugs cracked
Squish - The limit
Squish - A discussion on head design
Stator and Relay Diagnostic 
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator Removal on page 3
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix

#9 GSXLover

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Posted 14 January 2021 - 10:23 PM

OK. I've got some buddies that I've rode with since I was 21 and we got into it a little deeper. Bottom line, we found that the 12V at Fuse 11 dipped to 2V when you hit the start button. That indicated a problem between the voltage regulator and the supply side to Fuse 11. To prove it, we ran a jumper directly to the other side of Fuse 11 and hit the Start button and everything came to life - fuel pump, gauges, etc. Now the question is - where is the voltage regulator? I see from the schematic there's a ground connection to the frame at the regulator too. I want to check that too. Just don't know where it is on the sled. Can you direct me to it? Thanks.


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#10 codooster

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Posted 15 January 2021 - 12:19 AM

VR is on MAG side, in front of the engine, attached to the inside of the front pan (flat plate across the front of the frame where the nun attaches)  Pull the exhaust pipe to gain access. 


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#11 Daag44

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Posted 15 January 2021 - 01:30 AM

OK. I've got some buddies that I've rode with since I was 21 and we got into it a little deeper. Bottom line, we found that the 12V at Fuse 11 dipped to 2V when you hit the start button. That indicated a problem between the voltage regulator and the supply side to Fuse 11. To prove it, we ran a jumper directly to the other side of Fuse 11 and hit the Start button and everything came to life - fuel pump, gauges, etc. Now the question is - where is the voltage regulator? I see from the schematic there's a ground connection to the frame at the regulator too. I want to check that too. Just don't know where it is on the sled. Can you direct me to it? Thanks.

 
Brilliant!!! Hopefully you saw how an ohm/resistance test is in many cases useless. This is the reason that auto mechanics uses a test light as they can more easily and quickly measure voltage through sight of the light intensity.
 
With knowing the common problems of the 600 SDI, and having your results which again are top, there is most likely a problem with a splice in the wiring harness within about 6 inches of the fuse box. The only other problems that I know of is with the VR connectors and VR bridge circuit, but the splice in the Violet/Red wire near the fuse box is the most likely cause. The easy way to gain assurance in the splice is to turn the fuse box over and remove one of the grey tapes to inspect for corrosion. If there is corrosion, than it is nearly a guarantee to see it up the harness. If there is no corrosion, then start with inspecting the VR connectors. 
 
Either way, the VR connectors need to be inspected closely. A common mistake is the VR connectors being left not fully seated.
 
 
VRR - Voltage Rectifier Regulator connector issues
Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R P-TEK Electrical Troubleshooting #1 and #2 
800R Turbo
850 Center Oil line for coolant pump melted
850 Main Oil line caught fire #1 and #2
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's and Ronn's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Electrical - Diagnoses of a failed ECM
Electrical - 30A Battery Charging Fuse Socket Diagnoses and Relay
Electrical - Relay Coil Wine
Electrical - Relay Testing
Electrical - Battery Charging Relay Diagnostic 
Electrical - Troubleshooting with BRP video 
Electrical - Solder vs Crimp
Electrical - Diagram for Fanners on page 3
Engine Break-In 
Engine Weight 
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Electric Start troubleshooting
E-TEC Engine Management
E-TEC eRAVE position code recurring
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
E-TEC Voltage Rectifier Regulator troubleshooting
E-TEC Power Fades are not normal and can be fixed
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 Steering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Longevity - 800R E-TEC 
Mikuni o-ring for carb float assembly - Arctic Cat part# 6505-875 or from Amazon and eBay
Muffler Red Hot
Off-trail riding for flatlanders
Oil versus Fuel consumption
Pictures - How to resize and upload to DooTalk
Pictures - How to post with the correct orientation
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Power Loss - How to diagnose in the field
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Spark Plugs cracked
Squish - The limit
Squish - A discussion on head design
Stator and Relay Diagnostic 
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator Removal on page 3
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix

#12 GSXLover

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Posted 01 February 2021 - 03:42 PM

Hey Gents, Thanks for the help. I dug into the wire harness going from the fuse box back toward the voltage regulator and found the corroded wire - busted off completely at that point. I also found several others that I repaired. Took the sled to Norther Michigan this past weekend and it performed like its old self. Thanks again!


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