Have spark but Injectors won't fire - any ideas?

I have a 2004 RSV1000 factory motor in my cafe racer, which i am nearing completion, problem is that the wiring loom had to be significantly altered to fit the bike. As a result the injectors won't fire and the bike won't start. ECU not switching injectors to ground.

here is the diagnostic so far:

Spark ok, fire up with starter fluid manually sprayed into throttle body
Injectors have 14.5 Ohms resistance each
Injectors both have 12.50 V power supply
Injectors both have 2.5v approx on the ECU side terminal ( earth link side with ignition on and while cranking)
Injectors both manually fire when 12v applied direct and then earthed
NOID light stays on, no flashing.
TPS restisance fig are nornal
Replaced Cam sensor, just in case
Crank Position sensor, shows 850 Ohm resistance approx double the std spec but spark still fires ok.
ECU earth link wire has 1.5ohm resistance normal wire carries only about 0.1 or 0.2
pin B13 from the ecu should show continuity but is open circuit
ECU side of injector connector reads 40.5k Ohms resistance between terminal and ECU earth
Fuel pump primes and stops , does not run again after or during cranking
Immobilize removed and bypassed ( ok? )
Dash board removed
Sidestand switch bypassed, ( ecu thinks sidestand up )
Clutch switch bypassed to earth ( ie ecu think clutch pulled in)
Tipover still in situ and functioning
Neutral light functioning

Any ideas on where the problem my lay?

Question: Is 1) ECU is faulty or 2) the ECU earth link is carrying to much resistance or 3) low fuel pressure , the Fuel pump only primes then does not run after cranking starts therefore low fuel pressure

What are peoples thoughts?????

Any help much appreciated.

Thx
John

Thanks for your post and your comments

The "neutral light" was only a figure of speak.... It is tested with a multi-meter and has continuity when in neutral as it should.

Griff, Your two line reply was far more informative, rational and logical than Charles's 10 min phone conversation suggesting that the only solution was that i get a buy a new loom and a new dash and run it like that, even after it was explained that it was a custom bike and that the std loom does not fit without being cut ( lengthened) and that the dash can not be run (I think from the photos you can see why!!!) .....Charles also suggested that you can't cut any wires in the loom and reconnect them or the system won't work!! I checked all the cut wires for resistance before and after and they are ALL read between 0.1-0.2 Ohms same as the original uncut wires....and anyway he said he was not a wiring expert and only worked with std systems..... go figure!!! I expected a lot more from an "Expert" both in professionalism and knowledge. Sorry if you take offense to my view, but i have to say it how i see it, as you brought the Charles/Kickstart issue up.

Anyway, i have decided to ditch the Aprilia ECU and replace with the latest Haltech EMS at least Haltech know what they are on about and i have used their kit before with a lot of success.

Cheers
Norzilla

fusebox said:

no offence taken nor meant dude!!:thumbup

jus tryin to help out i was mearly suggesting that id spoken to charles about the fact that the conversation had taken place ....

i reckon your goin the right way with the aftermarket system dude , aprilia systems can be difficult to work with as they are desigend specifically for the mille , beside with most systems ...im not to sure about yours i must be honest , you get the telemetary....hhhmmmmm telematary!!:doug


i would be happy to help in the future if you get stuck or just need to chew the fat dude no worries!!!

hope all goes well!!
Griffer!!:thumbup

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Cheers, I appreciate the further comments and will keep in touch and the forum updated..

Thanks again

John

ps actually i will need to know cam timing, opening and closing for each cylinder to set up the sequential injector timing. know anyone who has that data?

amb67 said:

If this is as you say a CANBUS system then surely the ECU will be searching for an immobiliser too, if it doesn't see the immobiliser then this could be the cause of your lack of injector driver pulse from the ECU.

I understand that you say it has been bypassed but the ECU is expecting a signal back from the immobiliser unit, how have you managed to replicate an immobiliser response when it isn't fitted?

Sorry to respond with questions but this one puzzles me and I do like a puzzle. :thumbup

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Ah maybe you have it... I assumed that because i ran one of the immobiliser B wires to ground and got the spark back that i had fooled the immob. I will try adding the immob back into the system see if it makes a difference.

I am also concerned about the B pin that should show continuity in the earth loop but does not show anything?

Norzilla said:

Ah maybe you have it... I assumed that because i ran one of the immobiliser B wires to ground and got the spark back that i had fooled the immob. I will try adding the immob back into the system see if it makes a difference.

I am also concerned about the B pin that should show continuity in the earth loop but does not show anything?

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Tried it but no difference in outcome, problem may also exist in the fact that i don't have the dash and there is one lead that goes from the dash pin 11 marked H on the wiring diagram to the Immob then to the B28 pin marked H there is also B27 marked L and Dash pin marked L ?

amb67 said:

On any CANBUS system it will require all components to achieve a green flag status for the ECU.

When the system is first initialised it will hunt for the predetermined components and if they are not found and no bypass routine has been written in to the software then it will result in a red flag and hence a no go situation.

I take it that the donor vehicle was seen/heard running by you before you extracted the parts?

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Unfortunately no i did not see it running as it was a damaged bike. Thanks for your assistance, but i think that i have decided to ditch the Aprilia ECU to be replaced with the latest Haltech kit, then i will not have to worry about re-mapping issues when i get it running.

Cheers and thanks again for trying