Hi all,
I'm new here, but I've had an '08 650 from new. Presntly at 48000km.

A couple of weeks ago I rode through a puddle in the Brisbane CBD on my commute home from work. It was raining at the time.

By the time I arrived home I had an FI fault and following advice from here and my Dealer service manual (also via here) I quickly obtained a C40 fault code. I rode my other bike to work the next day.

The next evening my battery was dead, I charged it up and followong the fault codes in my manual I diagnosed a faulty ISC valve (open circuit on one winding). While waiting for a replacement I did the 48k major service, no issues to note.

After fitting and setting my new ISC valve by the procedure and balancing the bodies (using a nifty little gadget for setting the new ISC valve to step 58 ) my fault dissapeared and the world was good.

The next morning, halfway to work my FI light blinked on... After work, my battery was so run down the bike barely started. Once running and warm all was normal (aside form the glowing FI light) but it did'nt like to idle when cold.

At this point, I gave up and took it to my dealer. I did not tell them of my replacment of the ISC valve. They diagnosed a dead reg/rec, battery and throttle bodies based on the C40 fault, dead battery and poor charging. We discussed why they would recomend the throttle body replacement ($AU1600.00) when the C40 code clearly said ISC valve and they said the importer tech help told them C40 meant throttle bodies, although they noted all that 'stuff' was related.

On their advice (and lot poorer already) I decided to simply put up with the FI fault as the bike was running well.

24 hrs later my battery is dead again, my bike won't idle at all and I still have a C40 fault.

Which leaves me, well, dissapointed. Do I take it back to the same dealer, pay the $1.6k and hope their diagnosis is correct with no redress if that fails to fix it? (they already made it clear there were no gaurantees my $$$ would fix it and they could not return the parts once fitted).

Some reading around the web has produced evidence that others have suffered this same symptom set caused by moisture and/or a wiring or connecter fault. Is there anyone out there in veeland who has experienced this and could could offer advice?
Or any advice really, I'm reluctant to pay 40% of the bikes value for a repair that might not be effective...

Thanks,

Matt

Jeeesh

Get a Volt OHM Meter
search here for electrical tests

YOU can determine where your electrical problems are

Throttle bodies??... Just smile, wave and back away slowly... They are either ignorant, criminals, or ignorant criminals.

1 Ignore F1 codes for now
2 Determine if the bike is charging and fix if needed
r/r , stator and probably not rotor
3 battery charge disconnected off the bike and leave off attach right before ride. If still good then its good.

4 The wet might lead you to a short and or grounded something. You can also have corrosion products that short connectors internally. Unplug and examine/clean.

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Besides an ISC valve malfunction, a C40 can indicate a sticking secondary throttle valve or an ECM malfunction.

Trouble codes also can come from an out of range voltage reading. Make sure the bike is outputting at least 13.9V at 5000rpm. If not, check the stator for the proper resistance between the any two of the three output wires(all black or all yellow), 0.2-0.7 Ohms. Also make sure there is infinite resistance between any of the three wires and ground. The AV voltage output at 5000rpm between any two of the three output wires should be over 60V.

__________________
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

Thanks guys, I'll make a start tonight. The dealer did say they had checked the charging and it now fine, But..
I can hear the secondary throttle valves moving whne I open the throttle (motor not running) I can't say I've ever noticed this before as theres no need to open the throttle with engine off.

Matt.

That's normal.

__________________
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

Excellent, thanks for confirming that.
I have a 30 ohm resistance in the circuit that supplies the ISC valve. Removing the ECU, fuel relay and dash from the circuit makes no change to this. (I've not removed the ISC valve itself as yet, ran out of time).
The ISC valve windings have a 30ohm resistance (according to the manual). As there is nothing else on the circuit, and the ECU switches Neutral with no relay to protect it (!), it seems to me that I must have a ground in one of the 4 conductors between the ISC valve and the ECU. But when I measure that side of the circuit I obtain open an open circuit.
I guess I'll have to pull the ISC valve and measure it up next week when I get some more time.
Lucky my elderly BMW is as reliable as a rock...

Matt.

Found it.
One of the conductors between the ISC valve and the ECU had a dead short to ground. Because the ECU switches neutral there is no need to isolate the supply to the ISC valve when the bike is off. Becasue of the short one coil in the ISC valve remained powered up all the time, draining the battery and driveing the ISC valve to one extreme end of it's stroke. Causing one cylinder to get no idle air at all, therefore no idle. No vacuum though one of the two sensors will give C40 as will lowered voltage due continous electrical load on the stalled (end-stroke) ISC valve.
If anyone is still reading, you might like to check your wiring harness where it runs over (and sits on!) the ignition coil bare steel ground plates on the inside of the RH frame rail. Lift the harness 3mm and tie it up, you save may yourself a great deal of aggravation...

MattC

Good work. Thanks for the update.

__________________
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