Hi all,
On the way home from work a few weeks ago, my K5 DL650 died. It refused to start, and was a displaying an FI indicator and a flashing red light on the instruments. I had an instance in previous weeks of an FI indicator coming on, but the bike went into “safe mode”, so I could get it home. The problem seemed to appear after spraying ACF50 up onto the throttles; after removing the airbox, and cleaning all the injector and sensor connectors with WD40 Contact Cleaner, the bike seemed to be running fine again. Until it stopped completely when I was accelerating quite hard.
After getting the bike trailered home by my friendly neighbourhood AA driver, I used a jumper cable to put the bike into Dealer Mode, and got the C41 “Fuel Pump Relay Circuit Malfunction” error from it. I took the fuel pump relay off, and tested it with a 9V battery and a multimeter; the relay is fine. I assumed that the fuel pump had died, as I couldn’t find any other faults, but when I took the pump out and applied a 9V battery to it, it spins fine. When I plugged the pump back into the bike, I still had the same C41 fault, and no movement from the pump.
Stepping through the suggested tests in the service manual, I took the airbox off again, and checked the injector connections. Both injectors are getting power, and there seem to be no continuity issues with the injector wiring.
My next step was to try and eliminate a fault in the ECM, so I took pin 32 out of the ECM connecter and used the test method for determining the fuel pump output: apply the pin directly to the battery with the ignition on. Again, no action from the fuel pump.
I’ve done some other checks, and when I turn the ignition on, the orange/white on the fuel pump connector is getting 11 volts during start-up. The black/white wire has a path to earth (I get a current on the multimeter when I connect from the black/white terminal connector to the negative terminal on the battery). I’ve looked at the wiring diagram, but my electrical skills aren’t good enough to decide if that wire should have a path to earth or not (it's been a steep learning curve already trying to get the hang of using a multimeter, something I've owned for years but never used). I assume the power has to go somewhere?
So, as far as I can determine, the FP replay is fine, the ECM seems to be okay, and the fuel pump, which runs fine when a voltage is applied directly to it, is getting sufficient power when I turn the ignition on. But it’s not spinning, and I still get the C41 fault as soon as the bike has completed its 3 second start-up sequence.
Does anyone have any ideas what the fault might be, or what I should look at next to try and track it down?
Thanks,
Richard