Diag 1 Engine diagnositic '01 RSV

Hi,

Hoping someone can help me here...

Keep getting a DIAG 1 fault on the instrument panel. Only seems to happen after 5 miles or so of riding and then after grabbing a handfull of throttle. Don't know if it could be temperature related not sure, but when it happens the spark is obviously killed, further attempts to start the engine just result in the engine cranking, but not firing...wait 5 mins and she fires up again.

Have done a bit of a search on the forum and there seem to be various possibilities, such as; sidestand switch, datatool immob or loose starter wiring. Is there one conclusive fault to this code or is it a generic fault.

Here's hoping someone can help.

Cheers, tony

I dont know mate, but hope you get it sorted
( have a spare sidestand if you want it posting up to test/Swap )

OK, done a bit more reading (aprilia pdfs) since my initial post and does diag 1 always mean the TPS sensor is too far advanced? Judging off other posts on the forum others have had this fault and found it to be loose connections?

I've since connected the wires under the side panel and it doesn't always read Diag 1, but sometimes after the fault it does.:dunno

Cheers, Tony

Thanks for the offer Olek hopefully I'll just need to adjust the TPS.

Ok still suffering with this issue only its getting worse!! Had the 2 diag wires connected under seat and have played around with the TPS but I am finding it very difficult to get the dash to read zero and there seems very little sweep angle for the zero setting (I'm thinking a degree or so) and then it seems to want to go -1 or +1.

Does this mean I need a new TPS?

Cheers

The Tps can be a bit sensitive when you are trying to adjust it. The best way i've found is to slightly break the hold of the bolts, and not loosen them too much. The gently move the TPS until you get a 0 reading. It does take some patience. The reason I say this is because if you loosen them too much, there always appears to be too much free play and so if you do manage to find the elusive 0, then when you go to nip the bolts back up you'll peek up to the dash to see a +1 or -1 again :doh

I've re-read your first post. Are you saying that after 5 minutes of riding that diag 1 appears on the dash and then the bike cuts out from a total loss of spark? :dunno

Does it do that everytime you ride or is it intermittant? Does the bike have a pc3 fitted?

Hi,
Thanks for the reply.

No PC3 fitted to my bike.

Yes normally after 5 or so mins of riding the diag 1 will pop up and the bike cuts the spark completely - so abruptly that I have head butted the screen LOL. Last couple of rides the fault is getting more and more prevalent, typically at throttle openings less than full.

The time issue could be due to me letting the engine warm up and then normally the fault occurs after grabbing a handfull of throttle - but it has never happened the first time I open her up (could be coincidental). The fault NEVER occurs when I take it easy.

I've just been doing some more reading from previous threads related to the TPS and have read that I need to wind the adjuster out before I set the TPS, this I have not done so I'm off to the workshop to try it now.

Cheers

Yes you need to wind the idle adjuster knob all the way out before setting the TPS position. Remember to reset idle once you've finished

If it cuts out abruptly like that, then i'd hazard a guess it has nothing to do with the TPS as I dont think the TPS has anything to do with the spark timing. If the bike starts again after 5 minutes then I can't see that it is flooding and fouling the plugs after cutting the spark either, else you would have a bit of a barsteward getting it started again.

Have you had a look inside the airbox yet to see if the throttle bodies are opening and closing ok? It seems a little odd that it happens when you are grabbing a handful of throttle. Be interested to hear if it carries on doing it after you've got the TPS set to 0. You may well be right in thinking it is the TPS that is faulty. If adjusting it doesn't help and you want to eliminate the TPS as the problem, then give me a shout as I have a spare that I know works that you are welcome to borrow. Good luck :thumbup

Hello again,

Thanks again for the replies.

Have set the TPS correctly with the idle adjust fully disconnected and lubed all the linkages. Checked the butterflies for correct operation. All OK.

Fired the bike up, reset the idle and took her out. All was fine for the first 10 miles, the bike even felt smoother at partial throttle openings than ever. Then it happened again - the ignition cut when winding her up in first gear (probably at about 5K), I did not get the Diag 1 prompt, probably because I shut the throttle quickly so the engine didn't die. Had I kept on the throttle I feel the engine would have cutout. I've got to admit everytime this thing happens I need to wash my jeans, its that violent, to the point where I'm actually apprehensive to grab a handfull. Typically when it happens in first gear it feels like the back wheel locks. Historically the Diag 1 prompt has not always occured when the ignition has cut.

So I trundled back home, reconnected the diagnostic wires and backed-off the idle adjust so that I could check the TPS - it was still reading zero.

The reason why I originally thought the fault was the TPS;
a) because of Diag 1 on the dash
b) and I forgot to mention this - but when the fault happened for the first time I was really tanning the bikes arse into a high speed corner which has a hollow mid-bend. I probably hit this way too fast and it felt almost like the suspension bottomed, the spark cut mid corner and then it was a case of 'rodeo-time' until I fathomed the engine had cut and I grabbed the clutch. I had thought that the chain had snapped and caught in the swing arm!! Hence I thought that maybe the hollow mid corner could have loosened the TPS.

So after that little essay can anyone offer any more advise or things to check.

Cheers, tony

check out the tilt sensor it might have come loose on its mounting and when you are grabbing a handfull cutting the engine . its worth checking

OK cheers, I'll go and check that.
thanks

edit: have checked the sensor and removed the backplate. Resistance values are all in order.


Does anybody else have any ideas, I'm getting bit desperate now. Nice weather outside and the mrs has gone shopping!!

Cheers

Quick couple of questions. If you accelerate on part throttle does the bike continue to rev cleanly without cutting out? i.e does it only happen when you go for full throttle.

Have you taken a look at the sidestand switch? I am assuming that Diag 1 was coming on after the bike had cut out and not before?

Hi,

Thanks for the reply.
Yes the bike will rev cleanly at partial throttle openings and does not cut out, on the stand it will also rev OK without problems. The bike rides exactly as it used to before the issues started.

Yes Diag 1 only comes on once the engine cuts but sometimes not always :dunno. In addition if you stay on the throttle when it cuts it sometimes kicks back in. Let me put it like this; it is abrupt, almost like switching the low tension to the coil on/off.

Have not checked the sidestand switch, am aware of the issues with this - will do a little reading and a bit of fiddling in the workshop.

BTW this has only ever happened in lower gears I would say 1st & 2nd predominantly and possibly 3rd.

Cheers

Wondered about the partial throttle openings since it sounds like maybe it is vibration induced. The engines are pretty vibey anyway, so if there is something loose then it would make sense to me that when you throttle on hard that it shakes that something a little extra loose making the spark suddenly cut. Have a good check round to see if you can find anything loose including the sidestand switch, and if that doesn't cure it, the next things to check I guess would be the plugs. I've had a plug vibe loose and then out on me before. Mind you, you'd know if one had, it sounds like a very sick WW2 bomber :laugh also the tops of the caps can break internally (the internals stay on the tops of the plugs) which means sometimes you don't get a good spark.

Spoonz, LEGS, Griff or amb may well be along in a bit with some other ideas as to what may be causing it.

Good luck with getting it sorted :thumbup

Thanks again for the reply.

Ok so I have removed the stand switch and found that the 'potting' of the wires (where thay enter the switch itself) had really degraded and split - probably due to chain lubes etc damaging it. So I have removed all the potting to reveal the ends of the wires see below.



So to defeat the engine kill side of the switch I have to connect across the brown and black wires and if I leave the green one connected my dash light will still work? Is this correct?

I hope to then re-pot the wiring using some suitable gunk as a short term fix.

Any comments regarding the wiring connections would be much appreciated.

Cheers

Hi

Quick and desperate update.

Have done the mods to the sidestand switch to allow it to bypass the cutoff but still work the dash lights and have cleaned the engine cutoff switch on the handlebar.

Went out for a ride this evening and the bike is worse than ever - cutout on me 3 times and I had to wait at least five minutes each time before she would re-start (not due to flooding etc just not getting a spark). Each time this happened I got a EFI on the dash and then a diag 1, then the engine cutout leaving diag 1 on the dash.

In addition to the above stuff I have ohmed out the tilt sensor and reset and checked the TPS.

Anybody any ideas what the fault could be? Could it be an intermittent TPS fault? Would this cause the engine to cut?

Cheers

Hi, forgot to mention the cutting out has now started happening in any gear, tonight one one occasion I was simply tooling up and down the box at relatively low revs and it happened.

Cheers

Anybody any ideas on this please. Otherwise I'll have to grab the KY jelly and head off to the main dealer!

Cheers

Is there anyone near who could let you try their ECU box?

Hi,
None of my mates ride RSV's, not too sure if there is anybody on here?
Problem is now getting the bike anywhere to test?

Bit Pi**ed off at the mo. not had a good blast on her for nearly 4 weeks.

Cheers