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Ho hum, won't start

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scoffey View Drop Down
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    Posted: 12 Sep 2012 at 21:24
Hi all
After 18 months of all weather commuting I've finally picked up an elecky gremlin. Bike is an 04. The engine cut. Side stand light came on, lost neutral light. Problem cleared intermittently, bike would start but only run for a few seconds.
Present state on turning key, side-stand light on (even when by-passed), no neutral light, no pump prime. No starter when hit button, no clicking.
Reading 0.02V on the neutral switch wire with ignition on. Side-stand has been by-passed, as mentioned. Clutch-lever switch is dodgy, but would this kill starter if bike was in neutral? it shouldn't.
Got red triangle and 'err' but no code given when in fault state. According to the American cousins site, the above switches don't have assigned codes. I'm at a bit of a loss how to progress. Any ideas anyone? 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 12 Sep 2012 at 21:41
Sorry, should have posted in the tech areaSmile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tapmyhed Quote  Post ReplyReply Direct Link To This Post Posted: 13 Sep 2012 at 16:21
kill switch cable from handlebar.

Known to break in loom at headstock...would be my second check after the sidestand bypassed.

Sidestand bypassed: short circuit bypass or just cut.  Should be short circuit.

First check has to be everyones favourate....the tipover switch, under the seat.

Is it right way up?

Second to ast one for now.  Do you have an immoboliser...Meta??
These known to fail to make fuel circuits after being disarmed....usually wired into 2 strat/running circuits ie, fuel pump and starter solenoid...obviously solenoid would not make the bike cut out....but the fuel pump would.

Now the worse one: charging.  If your stator has gone, your battery may be below charge.  Bike might run, it might cut out....had this TWICE.  Check battery V should be 12.5 min if laid up, should be 12.5 to 13.5/14 if just on the charge...will settle back to 12.5.

If lower, battery problem, charge problem.  If you can get the beast to run, measure the V at the battery....anywhere from 13.5 to 14.5 is good.......12.5 or lower, pretty poor and is the problem.

Let us know how you get on.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote tapmyhed Quote  Post ReplyReply Direct Link To This Post Posted: 13 Sep 2012 at 16:27
NO!!! there is one more, forgot this one even though I fixed this on a mates RSVR....

OEM immoboliser, in the LH fairing at the front bolted to the inner fairing.  Has 7 wires in it....will cause alsorts of dashboard indications and a bike that runs/doesn't run....should read your post: all weather.!!

Its a sealed box, but the connections where the cables go in and are soldered onto the encapsulated PCB corrode and short out a bit.

Its fixable, but you need to expose the solder so you need to gently open it up, boths sides of the PCB about 5mm in from the edge.  Resoldering the cables is all you need to do, then reseal with rubber gunk (bathroom sealant!)

This is my number one for your problem...everything else in last post comes after this.

If your not sure how to fix it.....send it to me and I'll do it for free.  PM if you think its this.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 13 Sep 2012 at 18:41
Thanks for all that. Checked all wot you mentioned. My battery had dropped to 11.5, but this was after me throwing the switch about 20 times. I put it on charge overnight and got it back to 13V - still  no joy.
Here's a thing tho - downloaded a workshop manual today and a read of the electrical section reveals this:
On switch-on, a code is sent from the dash to the ECU over the CAN bus with the code of the installed engine. If this isn't received the dash goes into exactly the state I'm seeing. So I suspect its a continuity problem over the CAN lines. But where in hell should I start? - behind the dash I suppose....
anyway thanks for the heads-up
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tapmyhed Quote  Post ReplyReply Direct Link To This Post Posted: 15 Sep 2012 at 22:36
stock immob for me.  Thing is you cant tell by looking at it.....but it is so common a failure.

Not sure about the canbus theory.  I've had an 04 fac since 2006, racked up miles, had most problems you see on the forums, and this one just smacks of the stock immob.

The only thing I cant put my finger on is the err indication.  Coupled with all the other dash issues I would say you might have a dash issue, but that would not stop the bike running.  I had a dash problem where I lost indications and the rev counter was weird, but the bike still ran sweet.  I changed the dash and that was fixed for me.  The dash is only an output and is not linked to the immob or the ECU as an input. 

My mate has the gen2 rsvr 2003 and had issues just like yours...weird dash things, bike runs, bike stops....etc etc  it was the stock immob which I sorted out inside an hour.

Anyways....if your not sure, send it to me and I'll try it on my bike...if it causes issues I'll resolder it and reseal it.

Look at the dash immob light when the key is out.  Is it a clean pulsed blip or is the immob light dim between flashes....or just on all the time?



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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 09:17
The stock immobiliosor is part of the CAN bus. If it is fubar (which is 99% likely) you can get a CAN bus err and all manner of flashing dash lights, high idle, not start etc.

 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 10:00
Thanks for this guys. I'm a bloody electronics engineer but it doesn't seem to be helping. Went rooting and found these links.(see below) It's all as clear as mud - is the immobiliser on the CAN lines? - dunno, opinion seems divided. The circuit  diagrams are crap. All I can hear at the moment is that when I turn the key back off I get a brief, quiet purr from the dash unit.
The one thing which may be a clue is that when the fault was intermittant on the dash, the bike would still only run for about ten seconds, then cut. I was able to rev it, but it would always die. ANy suggestions on this? the dash might only be a symptom. Of course, it doesn't even do that anymore.The lack of an error code is galling.
The links below make for grim enough reading. I suppose I will have to go about changing out parts, if I can get my hands on them here in the ROI
cheers
 
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 10:44
Yes the immobilisor is part of the Can bus.
 
Cut it open, it likely has bad joint issues - resolder and reseal.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 11:11
Cheers mate
I'll try the immobiliser then - any tips on prising them open?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 11:17
cut round the seam on the sides with a sharp knife. When you open it up you will likely see really poor solder joints where the loom solders onto the circuit board. That is usually rhe problem.

Resolder it all and reseal it up with some silicone or similar and cross your fingers.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 14:25
Thanks Spoonz. Been reading instead of working this morning, and I learned stuff. For instance I now may understand why two wires to my immobiliser appear to have been cut once upon a time......
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 20:55
Update. My immobiliser is a replacement, from a Tuono, I reckon. Its deeper that the oem part, as far as I can tell from pix, with brown rather than black gunk. There were two cut wires going to it - I won't say which colour - where I reckon they'd by-passed the original to check the fault. (or am I wrong here?)
Wot I did next was, working on the above premise, short the same two wires together in the hope it would reveal another dud immob. But no joy.  
Question is, should I go ahead and butcher open this immobiliser anyway, or has my test revealed the bugger to be ok?
Goddam thing is buggin me now
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 21:18
The Tuono has the immobilisor built into the dash as far as i know

Has it got Zardi on it ?


Edited by Spoonz - 17 Sep 2012 at 21:18
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 21:49
Yeah, well ZADI, that is. Got a fatter profile than the pix I've seen - no gunk cracks, looks pristine. Like every goddam wire/connector I've looked at.
Had the dash open this evening - looks clean and fresh inside as the day it was made, pcb side
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 22:10
They rarely show any external issues, just naff internal joints.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Sep 2012 at 22:27
You're a gent Spoonz. I will operate tomorrow night. By the by, I pulled the ecu connectors tonight which made SFA difference to what I saw on the dash. So. Onwards and upwards.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tapmyhed Quote  Post ReplyReply Direct Link To This Post Posted: 18 Sep 2012 at 10:15
You dont have to reveal so much of the PCB, just enough to get to the solder points.
You may also have to gently scrape away the black stuff from the other side of the PCB.
The reason for this is when you solder, hot gases in the solder will try to pop through the solder you are using to resolder the wire onto the pcb.  This makes a bad solder joint.  If you scrape away the black stuff from the wire side, it gives hot gases another route out, making the soldering much better.

Just be careful you dont damage the wires when you scrape.

Fianl tip, and you'll probably know this, use leaded solder.  Dont use that ROHS lead free crap.  Its more brittle and may develope a thing called 'tin whiskers' over time, that grow and short out the wires.  Look it up on the net.  I work in an industry where we have control systems that have developed this strange thing, its only since our repair contractors started using lead free solder a few years back.

Anyway....your almost there!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 18 Sep 2012 at 18:10
Well lads, the damn immobiliser looks good inside. Solder joints are bright and neat, and when checked with a meter they're good. Will check them under a glass tmow, but my gut tells me they're good.(I've seen a lot of solder joints.) So no joy there.
I pulled the ecu connectors, and dash still just gives the same out - triangle, side-stand light, no neutral and 'err'.
At this stage I think its the dash. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 18 Sep 2012 at 19:31
Originally posted by scoffey scoffey wrote:

Well lads, the damn immobiliser looks good inside. Solder joints are bright and neat, and when checked with a meter they're good. Will check them under a glass tmow, but my gut tells me they're good.(I've seen a lot of solder joints.) So no joy there.
I pulled the ecu connectors, and dash still just gives the same out - triangle, side-stand light, no neutral and 'err'.
At this stage I think its the dash. 

Are both 30 amp fuses good bhind the batt.

Don't take it for granted the ecu is good because of the joints. I've never heard of a dash fail apart from the indicator relay (inside the dash on post 04) personally. First time for everything i guess.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joe 90 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Sep 2012 at 21:27
HELLO !! check the earth on the bike for corosion. all the earths on the bike that is. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 18 Sep 2012 at 21:36
More fun
Reckon it's the key switch. No power switching to ECU pin 36, no power switching to immobiliser. Got some power going to dash obviously, but none out to the above. There's an upper wire from the barrel to an AMP  two way, and a lower to a white six-way. The white has 12V available, but not switching through.  Anyone familiar with the switch arrangement - the bloody diagram is impossbile to read.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joe 90 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Sep 2012 at 21:51
if you have a immobliser fault you will have no power at the key switch, you can bypass the immobliser if you want to by cutting /connecting   ?????? anyway its as much use as a ash try on a motorbike. !!!  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 10:46
That was the wine speaking last night. I'm going to start again from scratch. First thing, how many ground points are there and where are they?
 
ps. interestingly, when the tacho settles down after it's first traverse, it goes back to 6000 revs and stays there!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 11:03
Originally posted by scoffey scoffey wrote:

That was the wine speaking last night. I'm going to start again from scratch. First thing, how many ground points are there and where are they?
 
ps. interestingly, when the tacho settles down after it's first traverse, it goes back to 6000 revs and stays there!
 
When it goes back to 6k does pushing any of the dash buttons make it scroll up or down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 16:55
A bit of progress at last. It seems the keyswitch is at fault. Its switching on two of its three poles, but not the one that switches power to the immobiliser and the ecu.
When I try bridging the switch out across the three pairs I get my pump prime and the usual noises. Unfortunately it doesn't clear the err, or the dash state, nor do I have starter motor or anything. Curiouser and curioser.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote stevezx7r Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 17:34
Could be that your just "hot wiring" the bike and missing the real problem?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 18:15
Originally posted by stevezx7r stevezx7r wrote:

Could be that your just "hot wiring" the bike and missing the real problem?

Know what you mean, but the diagram shows three pairs of wires connecting thru three switches at the key. When I check the switches, two are making but one isn't - the one delivering the immob, ECU supply, so....
Thing is, I can only have one original fault - how come I appear to have two nowConfused
ECU fecked by original fault????
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Post Options Post Options   Thanks (0) Thanks(0)   Quote stevezx7r Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 18:25
If you know a decent auto lecky I'd take it to them to have sorted before you make things worse....done it myself, many times ;)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoffey Quote  Post ReplyReply Direct Link To This Post Posted: 19 Sep 2012 at 18:43
Originally posted by stevezx7r stevezx7r wrote:

If you know a decent auto lecky I'd take it to them to have sorted before you make things worse....done it myself, many times ;)

Oh ye of little faith, Steve. Where I live here in the west of ireland there ain't no bike lecky's I'd trust near it - and Prillers are like hens teeth here, too.
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