Diagnosis Please!

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RSVDUG

Joined
Jul 16, 2009
Messages
12
Hi All

My ultra reliable 2002 RSV Mille has now got the following:

Turn ignition on, hear fuel pump priming.... then click from under seat and fuel pump priming noise again..... then click and fuel pump priming noise again...etc.

Started fine, drove for about 40 feet then engine dies completely. Managed to get home with 3 restarts...

So is this the starter solenoid on the way out or something else...?

Thanks for any help.
 
Possibly sidestand switch or tilt sensor as first options to check. Solenoid may be on its way out but would not stop the engine.
 
Hi - thanks for the reply.

I've just disconnected the side stand switch, turned ignition on and what I'm getting is one or two of the relays under the pillion seat constantly clicking away and the fuel pump continually re-priming - would you expect this behaviour with the side stand switch disconnected?

Or does this suggest something else? (The battery is the uprated version and bike is kept on trickle charger and healthy)

How do I bypass switch - is it shorting the outer 2 pins? Or does the above relay clicking suggest problem is elsewhere?
 
sounds like the ignition power is being interrupted, bit like turning the key off then back on straight away.
if the tip over switch and sidestand switch are ok then have a wiggle of the ignition key and ignition switch connector - maybe righthand switch gear connector or even the kill switch itself has poor connection.

could even just be poor earth feed somewhere - are the battery terminals nice and tight?

RSVDUG said:
Hi - thanks for the reply.

I've just disconnected the side stand switch, turned ignition on and what I'm getting is one or two of the relays under the pillion seat constantly clicking away and the fuel pump continually re-priming - would you expect this behaviour with the side stand switch disconnected?

Or does this suggest something else? (The battery is the uprated version and bike is kept on trickle charger and healthy)

How do I bypass switch - is it shorting the outer 2 pins? Or does the above relay clicking suggest problem is elsewhere?
Click to expand...
 
Hi - an update: Took the relatively new battery out and recharged it overnight. Back in this morning and things a bit different. Now there is no fuel pump noise at all - just a click click click from seat area. I measured the battery voltage in situ during clicks and was 13.5V.

Any new suggestions?
 
Hi, Bypassed the side stand no diff. However now pretty sure it is the tilt sensor switch - how do i bypass it to test?
 
Sorted! I took the fall sensor off to do the resistance measurements when switch is upright and over by more than 45 degrees. Resistances fine, put back in now bike primes fuel pump in correct manner.

Should I put it down to a dodgy connection or should I replace sensor? Guess new sensor is the safer option....

thanks for the replies
 
Hi..... think I need to re-open this case.... Decided to have a look inside tilt switch to see what was in there. All looked fine, put back in bike but could not get pump to prime, just click,click. Thought maybe when I was originally moving tilt switch to get fuel to prime I was actually moving some other wire in that area. Sure enough started moving some of the wires and intermittent priming begins. The wires coming from the 2 30 amp fuses seem the guilty party but still hard to say. I can eventually get to the point where the pump primes correctly.

So, I have a dodgy connection somewhere(!?) Out of interest what do those fuses feed?
 
Try looking at the wiring coming out of the fuel pump, has been known to fail or be dodgy at the connector which is located under the seat. All you need to do is leave the ignition on and wiggle the wires. Worth a try.
 
Hi alwaduk

This morning I lifted the tank and there is a connector with 3 wires just under the LHS of the air box which I think powers the pump. I tried to pull this off, but failed (is there some latch holding the connector on?) gave it the good old wiggle and since then the pump primes correctly on each turn on of the ignition. So this could be it - so what now? Can anyone tell me how it comes off so I can inspect the connector terminal etc?
 
Question : Got the connector off; does it plug in so some sort of small pressure sensor device? There are 2 very small rubber tubes, one from each cylinder which go to a T-piece and the other end of the T-piece is a small rubber tube into the DENSO device. With the connector unplugged, pump primes correctly, on plugging it back in I can still get the intermittent priming. Is this some sort of pressure sensor the sends a signal back to the ECU to say "pump primed"? When it is disconnected am I "fooling" the ECU into thinking pump has primed? Are these sensors known to fail?
 
Pictures might help
This is what mine looked like

It was both dodgy wiring and dodgy connector. I fixed wires and put a cable tie around the connector to hold it tight together and you should put some sort of conductive grease in there as well. You can if you want do away with the connector altogether just to be sure but then if you ever need to take the tank off completely it would be a pain.
One end of the wires goes into the fuel pump and the other into the loom and power if i remember but a wiring diagram such as in the back of a Haynes manual would tell you better than me.
If memory serves it is the blue wire that runs power to the fuel pump and the one i had problems with.
Does this look like yours?
 
I'll have a look at the wiring later. What is apparent today is that with the tank in the raised position the "fault" has all but gone. I guess this is pointing towards the wiring of the fuel pump at the rear base of the tank
 
Another day, a slightly different scenario.... Lifted tank in prep for removing tank etc and the intermittent problem is there. Check connector feeding power to fuel pump, wiggle wires at base of tank - did not seem to make a difference. The fuel pump starter relay is the one clicking away. Took it out, put it back in, and problem "seemed" to go away (been here before!) Started bike, ran for about 10mins no prob. Did the same thing about 1 hour later. Then thought it did one intermittent click click. Swapped the engine stop relay with the pump relay and bike starts fine and runs without cutting out. Now, I'm not saying this is the definitive answer but its the nearest yet - think I'll renew both relays and see how it goes.
 

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