2009 R6 fans don't run even at the high temp warning point.
- fuse checked
- hooked the fans up to the battery directly and they both work
- thermostat causes the radiator to cycle the fluid (thermostat should be fine?)
I'm guessing it's probably the fan relay switch? I have no idea where it's located but guessing if there's no break in the harness from the switch relay to the fan fuse box location, it must be the relay itself.
Any other suggestions? Any help would be greatly appreciated.
Does the coolant temperature display on the dash read the correct coolant temperature? Your fans are supposed to come on when the coolant temperature display on the dash reaches 102c (216f).
Your fans are completely controlled by the ECU. Try testing them in diagnostic mode and see if the relay is functioning and the ECU control signal is working properly:
Your service manual:
http://ecuflashking.com/r6/manuals/2008-2011 Yamaha R6/2008 Yamaha R6 Serivce Manual.pdf
Diag mode:
1. Set the kill switch to STOP.
2. Hold down the select and reset buttons and turn the key to ON while still holding them down.
3. After you continue to hold the select and reset buttons for about 10 seconds the dash should say "DIAG". Release the select and reset buttons and then hold them again until the dash says D01.
4. If you twist the throttle you should see the D01 number go up and down, D01 is your throttle position sensor test.
5. You can press the select or reset buttons to cycle through all the tests.
D06 is the test for the coolant temperature sensor (just reads out the currently sensed coolant temperature) and
D51 is the radiator fan motor relay test. It will actuate the radiator fan motor relay five times at one second intervals (ON 2 seconds, OFF 3 seconds) and also illuminates the engine trouble warning light. If the D51 test doesn't produce any reaction from the motorcycle try it again with the kill switch set to RUN or cycling the kill switch while the D51 test is selected. Use extreme caution using diag mode with the kill switch in the RUN position, if you hear your fuel pump running for more than 5 seconds turn the kill switch back to stop or if that doesn't stop the fuel pump turn the key to off.
Troubleshooting steps start at page 354 of the service manual (8-31) with the radiator fan motor relay inspection/testing procedures in the lower left of page 413 (8-90).
I've seen this problem twice before, when people either connected their main battery backwards, or were boosting it and connected the booster cables backwards. It damaged the fan relay controller inside the ECU. Wiring up a manual fan switch fixed the problem (you just turn it on to cool the bike down) or you can replace the ECU. If your bike is a canadian bike (has red blinkie light in tach gauge) then purchase a replacement ECU from the USA (approx $150, any 2008 to 2015 ECU will work) and I can modify it to work on your bike. If your bike is a USA bike (no red blinkie light in tach gauge) then any 08-15 USA ecu will work in it without modification. To buy a Canadian ECU from yamaha would cost $2800 and you'd have to replace your ignition, keys, gas cap and trunk lock, that's why you go the USA ECU route.
I'm just in Whitby if you want to bring your ECU by (or if you think it's safe enough to ride your bike down) I can plug it into my laptop and run the fan control test as well as reset the eeprom values for the fan turn on and off temps (and I could temporarily set them way lower so it doesn't have to get to 102c before it's supposed to turn your fans on). I also have a spare ECU we could try in your bike (or you could borrow to help in your troubleshooting). Everything I've mentioned above (with the exception of converting a USA ecu to work on a canadian bike) would be free of charge. You can text 289-600-9937 if you need to get a hold of me (calls don't work).
Good luck!
