ECU Replacement. Possible causes, or random failure?
This got a bit long, but I wasn't sure how much I could shorten it. Sorry for that...
New member here, and long-time lurker. I have had a 2006 DL1000 for about 4-1/2 years now, with no problems at all until right before Christmas. I had, around Thanksgiving, removed the body panels to route the wiring for some Oxford Sport Heaterz, and while I was in there I cleaned the K&N air filter before putting everything back together. I don't have a lot of time to ride at the moment, but I rode it for about 4 miles total, just to try the new heated grips, plus a Givi windshield I had also acquired. Got home, parked the bike in the garage, and didn't get back on it for a few weeks. It ran perfect, and the grips were great! Much warmer than the cheap ones I took off.
So here's the deal: I suited up to ride to town on the Saturday before Christmas, and got out to start the bike, and...no fuel pump. The battery is healthy, though I'm not sure how old it is, and was cranking the engine over fine. Everything seemed to work, except the fuel pump. The gauge needles would sweep on startup, like normal, but I did have "CHEC" on the display. I have the factory service manual, so I got that out and started tracing things down. All the safety switches seemed to work, fuses were fine, and I figured out that the fuel pump relay is grounded through the ECU, which, at this point, wasn't happening. I looked for all the threads on here and VSRI about these symptoms, and found the different ones about checking the safety switches, the plug to the digital display, etc. Nothing seemed to totally match my symptoms, so I ended up sourcing a used ECU and ordered it.
In the meantime, I tried checking more wires and fuses (again), and ended up discovering the threads on here and on VSRI about the key switch resistor, so I tested that and it showed 99.x ohms...basically perfect. I also read about the 5V wire between the switch and ECU, so I backprobed that wire, found about 1.1 volts there, and thought I had a bad key switch, so I ordered one of those. (I do NOT like simply throwing parts at a problem, so I was starting to get nervous. I've done that a few times on other vehicles before I knew what I was doing.) The new key switch (off a 2012 Vee) didn't change anything, and i couldn't find anything wrong with the other wiring, sensors, etc., so I nervously swapped the new ECU in and turned the key. SUCCESS! Started up and ran without any noticeable drama.
So now, my questions:
1. When hooking up the Oxford Heaterz, I put the little control box (not the one with the buttons, the other one) in that little gap between the ECU and the fuel pump relay. I can't cut and shorten that cable, since it's got a big multi-pin plug between that box and the one with the temp. control buttons. Is it possible that there was some kind of electrical/electromagnetic interference that box put out that ruined my ECU? I didn't hook the grips back up yet, I left them unhooked to try running the bike with the new-to-me ECU. Do I need to move the wires around?
2. The wiring on this bike looks PRISTINE. I checked a bunch of plugs for bad connections, broken/bare/burned wires, etc., like I read about others dealing with, and found none of that. Was this just a random failure?
3. I was nervous about hooking the new ECU up, because I hadn't found anything else that looked bad, and I didn't want to miss something that might fry it again. I haven't had time to put it together and ride it, but it seems to run fine in the garage. Did I miss something that I should check?
4. The ECU I took out was labeled 06G70, and the new one is marked 06G71. Anything different here?
As far as I know, the bike is completely stock, except for heated grips, K&N air filter, and Eastern Beaver headlight relay kit with one headlight cut-out switch, all of which I have installed after I bought the bike. None of the factory wiring has been cut or spliced, the grips and the headlight kit are both hooked directly to the battery with inline fuses.
Sorry for this epistle, I was just trying to get all the pertinent details in. Any ideas or suggestions? Let me know, thanks.