Author Topic: Bike died (Read 1684 times)

welldc · « **on:** August 07, 2020, 13:56:05 »

08 650 ABS
Bike ran fine to fuel station. Filled up, tried to restart, dash lights flashed once and then nothing. Needles would flick around the clocks but no ign/abs lights. No headlights.
Managed to jump start the bike bet ign light stayed on and F1 flashing on dash, then it died again, dead as a dodo.
Recovered home (that's a story in itself).

New battery fitted just in case, though I have charged the old one and its holding 13.2 volts.

Checked charging rate (expecting stator issues) and its charging 14.3 volts at 4000rpm+

Just put in dealer mode and comes up with Code 0031 which according to my research is gear position sensor.
The aftermarket gear indicator has gone blank.
Does any of this make sense?

Brockett · « **Reply #1 on:** August 07, 2020, 14:46:16 »

Gear position is an ECU issue and I do believe the after market do dab also collects info from ECU

welldc · « **Reply #2 on:** August 07, 2020, 15:16:54 »

Just re-read my post.

Omitted to say that with new battery bike starts and runs, but ign light and F1 are still lit.
It sounds fine and responds to throttle but I have'nt ridden it, so no load on engine.

tallpaul · « **Reply #3 on:** August 08, 2020, 07:46:47 »

I know the the gear position sensor gives a specific output to the ecu based on which gear it is in. If the ecu isn't seeing an input from this unit then it will give an error. How is the GPI connected? Could this be removed from the circuit and see if the problem goes away? It may be the GPI that is causing the issue.

Ianmc · « **Reply #4 on:** August 08, 2020, 07:59:19 »

I didn’t think that the 650K8 had a GPI,only a neutral switch.Where does the aftermarket GPI get its signal from ?

tallpaul · « **Reply #5 on:** August 08, 2020, 08:02:26 »

There is still an output on the gearbox for the ecu. A few years ago Bigpie came up with a circuit for making a diy gear position indicator. I and few others fitted them and the one fitted to my old bike is still going strong. There is a thread on it somewhere in the depths of the forum...

tallpaul · « **Reply #6 on:** August 08, 2020, 08:11:35 »

https://www.v-strom.co.uk/smf/index.php?topic=24202.0

The above thread is for the Bigpie unit.

tallpaul · « **Reply #7 on:** August 08, 2020, 08:13:05 »

https://www.v-strom.co.uk/smf/index.php?topic=31726.msg313917#msg313917

A good diy thread with more technical information in it.

Ianmc · « **Reply #8 on:** August 08, 2020, 10:55:00 »

Thanks Paul, interesting mod, but personally I have never had one so don’t miss it.As long as the neutral light works I am happy.I am a bit old fashioned and find new technology sometimes is just a fad and something else to go wrong to make loads of money for the dealers.(A bit of a “Luddite” really.)

welldc · « **Reply #9 on:** August 08, 2020, 13:11:29 »

What puzzles me is that original symptoms were total loss of electrics and flat battery, therefore, not charging or sudden battery failure.
With new battery, it now starts easily and runs fine (only tested without engine load).

I suspected failed stator but it's charging at 14.3v.
I'll try disconnecting the add on gear indicator, but it only seems to piggy back the feed from the gear selector.

So is the electrical failure and gear thing linked, or a coincidence?
I'll get the old battery tested under load, but after charging it off the bike it was holding 13.2v.

Brockett · « **Reply #10 on:** August 08, 2020, 15:09:28 »

For no sound reason I suspect a short / break in the wiring that is still lurking to strike again.
Is the ign light and FI still showing?

welldc · « **Reply #11 on:** August 08, 2020, 17:56:41 »

Yes, both still showing. Electrics obviously disconnected when battery changed.

dealer mode shows C0031

sjrainsford · « **Reply #12 on:** August 09, 2020, 11:03:35 »

I’d personally remove the gear position indicator and put it back to standard. Then disconnect the battery for a few minutes. Then reconnect and try again.

Also it wouldn’t hurt to have a good check over the usual suspect plugs that reside above/ near the top of the radiator.

RoadWarrior1978 · « **Reply #13 on:** August 12, 2020, 08:45:30 »

According to my DTC table, code C31 = Gear position signal voltage is higher than the specified
value.

It would be possible the GPI has an internal short or there's a wiring fault. Hope that's some help.

welldc · « **Reply #14 on:** August 12, 2020, 18:50:29 »

Cheers. I'll have a look at the wiring as soon as I get chance.
Maybe a short/break somewhere would explain the sudden loss and the fact its running again now, albeit with warning light and message.

kwackboy · « **Reply #15 on:** August 12, 2020, 19:20:53 »

Knowing Suzuki electrics of that era I'd have a look at the large block connector behind the front left part of the fairing, in fact I'd check all the usual suspects including behind the radiator.

Sometimes the connections burn out and can cause a short.

I'm happy to be wrong but I personally think the 0031 error code is miss leading you.

welldc · « **Reply #16 on:** August 13, 2020, 19:03:22 »

Thanks Kwackboy. I'll get stuck into that.

Silverback · « **Reply #17 on:** August 13, 2020, 22:15:40 »

I agree with kwackboy, remove left tank fairing and check the large block connector for corrosion.
Had similar problems with my k7..when I wiggled that block connector the dash would do all sorts of weird things including throwing the needles back and forth. From what I remember I also got a code displayed.
Didn't get the flat battery though. I replaced some of the pins rather than the whole connector.

welldc · « **Reply #18 on:** August 14, 2020, 15:15:45 »

I've managed to get to the large connector block (on the left side of the bike).

It has a rubber shroud on the loom and the block and connectors are pristine. Seperated the connector block and all the pins are clean with no signs of corrosion or burning.
I did find part of the loom going through a U shaped guide which had chafed through the outer covering, but the wires inside were intact. Taped up and relaced.

V-Twin · « **Reply #19 on:** August 14, 2020, 15:48:11 »

What about the cables that goes under the centre frame section?
Wasn't there a Factory recall on this?
Maybe worth a look.
See Pic, just under the silver section, might need to remove the black side panel?