even the factory shop does not have diagnostic capabilities for the ECU.

poor design on Suzuki's part, replace with known good ECU is only testing option, and ya don't have to be a Suzuki tech to figger that one out

I went thru everything you have and more, however we knew what my problem was cancer of the wiring due to riding in corrosive winter conditions

I ended up replacing entire wire harness and all sensors but not the ECU

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Yes, the bike is warmed up with at least two bars on the gauge. I have not drained the tank, though. When it was "put up" when I left for deployment Stabil was put in the tank. I haven't changed it yet. Do you think that will cause a "huge" problem? I know I need to drain it and start over. But here we are with the "what to do with all of that gas" delimma. At the very least it will make working on the bike that much easier because I won't have to pick up a full tank all the time!

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You can't fix stupid!

Pain is weakness leaving the body!

I'm REALLY hoping I don't have to dig into the wiring too much! What I am going to try to do is to work through the "after-market wiring" to clean it up some and see if I can't get it back to "factory".

__________________
You can't fix stupid!

Pain is weakness leaving the body!

Did you look at flea bay for a unit? Saw some for 02 models (fair price , same p/n @ Bikebandit as 03) , might be an option. Also , did the shop tell you what aftermarket dodad was the culprit of this fun you are having? Just curious , as these bikes seem to be heavily abused in the electrical dept. by people.

BTW , my 03 had a burned up stator and roving magnets........

Dan

Oh we've been through the stator/magnet issue. All of that was changed, but it really wasn't the issue. I did check on eBay and saw one a month or two ago CHEAP, but didn't move on it. The shop said that a "timing retard indicator" was the culprit. It has been removed now by the shop (I think).

__________________
You can't fix stupid!

Pain is weakness leaving the body!

If....

You were NOT in a climate controlled space or inside with heat

The tank was not filled to the very brim as in up the neck then you could have cracked the alcohol phase out of the gas and she would be dead.

Some water / alcohol phases actually grow life and become a gooey sludge

b4 u sink big dollars take this step of draining and flushing

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Unfortunately you lost me there. As far as I know (& admittedly I did not look to verify) the tank was "full". Other than that I'm at a loss.

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You can't fix stupid!

Pain is weakness leaving the body!

I know this in an old thread and most likely fixed by now but my 2 cents worth. My Vee had a similar issue ultimately breaking down on the road. Back flushing the fuel filter attached to the pump showed the filter to be completely clogged. I replaced only the filter portion of the assembly and it was less expensive than the entire unit. I believe the fuel pump and filter assembly is around $1000?!?

All DL1000s and DL650s before 2007 use the same pump. Mrcycles.com lists it for $623. They can use an external filter bypass method. External Fuel Filter modification

2007 and later DL650s have a fuel pump going for under $500 but it does not allow a bypass.

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Pat- 2007 DL650A was ridden to all 48 contiguous states. 2012 DL650A is just getting started.
Nicknames for posting ease on my part, Vee = all DL1000s. Wee = 2004-2011 DL650s. Glee = 2012+ DL650s

I was not aware that the 2007 and up were made in such a way that a by-pass is not possible. Hopefully, the pump/filter combo's in these years last for a very, VERY, long time. At least it is a little cheaper than the pre-07 models.

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