.: XT660.com - The #1 XT660 Resource :. - Engine cutting out fault codes

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.: XT660.com - The #1 XT660 Resource :. ( https://www.xt660.com/index.php)

- Performance Modifications & Enhancements ( https://www.xt660.com/forumdisplay.php?f=52)

- - Engine cutting out fault codes ( https://www.xt660.com/showthread.php?t=13441)

Denny

10-05-10 21:06

Hi Medo, hope you're ok & not working too hard :)

Quote:

Originally Posted by medo (Post 127670)

Please, take your multimeter again and put it on DC Volt with scale 20 ... that's 3 steps counter clock-wise from OFF position ... connect back all plugs except sidestand switch cable connector ... turn ignition key ON, gear in engine and put engine kill switch to STOP position ... now use RED clip of your multimeter on blue/green wire and BLACK clip on black wire of the sidestand switch plug - loom side ... you should have reading around +4.5 Volts ... if so, try to clear fault codes history by entering diag mode - code no 62 (engine kill switch set to RUN position when entering diag mode code 62; turn it over to STOP position and back again to RUN position)

Result for this test was as you said...4.35 on the multimeter.

Quote:

Originally Posted by medo (Post 127670)

if your multimeter shows nothing than use RED clip on blue/green wire and BLACK clip on battery negative terminal ... if reading is around +4.5 V then black wire is not connected to bike's chassis (battery negative)

4.35 for this too.

I also tried to reset the fault history in diag mode, but as was the case previously I was unsuccessful. Code 62 still showed a reading of 1 fault. When I flicked the kill switch to ON the bike made that whirring noise it makes when first turning the key to start the bike(not sure if this is right but is this the petrol pump priming, similar to cars?). When I flicked the kill switch to OFF the noise went...but the fault didn't clear.

Thanks
Denny

Denny

12-05-10 17:09

Medo, Kev...I'm at a stage where I have to have my bike running. Extremely grateful for all your input so far, and would be further grateful if you could give some final advice (which will hopefully have the bike working) before I load the bike on a truck & have her fixed by the stealers....

Thanks
Denny

Kev	12-05-10 23:22

Quote:

Originally Posted by Denny (Post 128610)

It is rather hard sometimes to do electrical fault finding on a bike when you can't see a thing & relying other persons skills to do it for you. Even though you have done a great job we have missed something. It still could be the ECU or fuel pump main relay at fault. Let us know how you get on.

Denny

13-05-10 00:17

Quote:

Originally Posted by Kev (Post 128646)

It is rather hard sometimes to do electrical fault finding on a bike when you can't see a thing & relying other persons skills to do it for you.

I have the utmost respect for you and Medo for all your help. I fully appreciate the fact that not all problems can be sorted online and that you have both helped me out as much as possible, which I am extremely grateful for :)

I will be calling the roadside assistance first thing Saturday morning in order for them to transport the bike to my local Yam service...and hopefully will have some sort of verdict by close of play. I will keep you guys informed ;)

Kev	13-05-10 02:04

keep us posted.

medo	14-05-10 19:10

As usual I'm late with reply

Hope you'll be having your bike running very soon with minimum cost of repaire

Denny

18-05-10 10:17

Right...well it's not looking good, in fact it's piss poor!!! Just got off the phone to the dealer...the ECU is dead :(

I've been quoted approx �435 for the ECU only...does this sound right?

Should I start scouring ebay or just front up and pay the barstwards for a new one? The dealer told me that I would need to buy a new ignition set with it as a used ECU will not work with my current immobilisers security codes. Nor can either be programmed to suit the other.

Time to make a post in the 'How reliable is your XT' thread me thinks.

:( :( :(

ps. the bike is an '06 XTX. I'm really crap when it comes to searching for new/old bike parts online, grateful if those that can post some links to sites that have what I need.

also, do I need anything other than the ECU when it comes to the swap...like wiring looms/etc?

thanks
Denny

medo	18-05-10 21:22

bad news if ECU is malfunctioning

don't know about fair price for the new unit but I have a look at some yamaha papers and found that when ECU unit is to be replaced there is no need for immobilizer replacement ... Kev ?

http://free-du.t-com.hr/medo/yam.jpg

Kev	18-05-10 23:20

Quote:

Originally Posted by Denny (Post 128970)

I just fitted a brand new 06 ECU (01) to my 2009 XTX, bought from the UK for 105 Pounds a week ago. So where do they get 435 Pounds from?

You can not recode a used ECU to run on another XT660, so you need a new one.

Tell your Yamaha dealer to use the part number 90891-30032 shown in the Photo it cost 105 Pounds.

Read here.
http://www.xt660.com/showpost.php?p=128913&postcount=59

Denny

19-05-10 10:25

Ok guys, that's really helpfull, and good to know that I can get the part cheaper!

Just to clear things up, the dealer said I need to order the ECU according to my bikes chasis number. Is this correct, or can I just order an '06 XTX ECU?

*edit*

I just got off the phone to the dealer...he told me the part number is 5VK-8591A-01 which he said is the CDI. Not sure if that's the same as an ECU but the part numbers differ?

He also told me to change the 'rolanti' (turkish, don't know the english) which has part number 5VK-81950-40

Thanks
Denny

Kev	19-05-10 12:31

Quote:

Originally Posted by Denny (Post 129023)

All the info is in my post above.

Have a look at the part number on my new ECU it has the same number you are quoting above.

You will pay 450 pounds if you order it as this part number 5VK-8591A-01 , look at the part number on the packet on the photo below, if you order it as that part number you will pay 105 pounds, same part different price.

I have bought this superseded ECU twice one for my 07 XTX & now for my 09 XTX using a 2004 wiring loom. As long as your XT does not have a O2 sensor this superseded ECU will work on all 2004 to 2006 models, at quarter the price.

Ask your dealer to give you a price on a 90891-30032, it will fit all years 2004 to 2006 with no O2 sensor, I am 100% sure.

What is a rolanti, can you show me a photo?

http://i201.photobucket.com/albums/a...x/DSCF3206.jpg

Denny

19-05-10 13:59

Kev, I just called the dealer and they don't list part number 90891-30032

I only just managed to look at your picture (work restrictions), the part you have shown has a sticker with part number 5VK-8591A-01. With the part number 90891-30032 on the bag. Doesn't that mean they are the same thing?

cca	19-05-10 16:20

rolanti?

http://www.boats.net/parts/detail/ya...950-40-00.html

Denny

19-05-10 18:32

Quote:

Originally Posted by Denny (Post 129033)

Alternately could you tell me how you ordered your part? I tried again with the dealer with no joy. The part number on the ECU itself is the only thing they could find on their system.

medo	19-05-10 22:04

http://www.cmsnl.com/products/xt660-...ol_9089130032/

168 Euros for ECU ...

5VK-81950-40 is part number for fuel injection system relay unit

Kev	19-05-10 23:18

I saw a fuel pump relay on Ebay the other day.

As I said it is a superseded part number, I have ordered this superseded part number twice directly from Yamaha bike shops.

It will fit all XTX & XTR models 2004 to 2006, with no O2 sensor. The reason I got both of them from the UK was it was cheaper from there then buying it from Oz, this part number has been around since late 2005.

I discovered it by chance when I had my 04 XTX ECU changed under warranty, it was to be used when a bike was under warranty & the ECU was to replaced, I saw the part number on a packet when they changes my ECU on my 04 XTX in 2005. So it is same ECU, just has different part numbers, one price for Yamaha & one price for us.

When ordering the superseded part number you can be sent a 01 or a remapped 00 with white paint dot ECU both have the same mapping.

If your bike shop was any good they should be able to check superseded parts from Yamaha.

Denny

20-05-10 09:41

Quote:

Originally Posted by Kev (Post 129052)

When ordering the superseded part number you can be sent a 01 or a remapped 00 with white paint dot ECU both have the same mapping.

So they will both work on my '06 XTX?

Rather than faff around with dealers I called Yamaha Turkey directly. They found it...it's �150...will take at least a month for it to get here :icon_frown:

I might have to kindly ask my good friend here if he will do me another favour & lend a helping hand :)

*edit* Could you possibly send me the details of the dealer/place in the UK you ordered the ECU from, that way I can be sure that I am ordering in the correct part? Maybe I can get them to send it to me direct? Thanks

CaptMoto

20-05-10 10:20

Quote:

Originally Posted by Denny (Post 129066)

Denny if you need any help from me, just ask. Like we did last time for those parts you needed from Yamaha.

Kev	20-05-10 11:40

You use the part number on the packet when ordering.

Here you go for the relay.

http://cgi.ebay.co.uk/YAMAHA-XT660X-MULTI-RELAY-CONTROL-UNIT-XT-660X-07-/110502203914?cmd=ViewItem&pt=UK_Motorcycle_Parts&h ash=item19ba71d20a

Denny

20-05-10 12:05

Capt'n you're a gent, I'll be getting in touch soon :thumbsup:

Thanks for the link Kev, much appreciated :) I noticed it's off an '07, will that work with an '06?

Kev	21-05-10 02:05

Quote:

Originally Posted by Denny (Post 129077)

Capt'n you're a gent, I'll be getting in touch soon :thumbsup:

Thanks for the link Kev, much appreciated :) I noticed it's off an '07, will that work with an '06?

Check the part number on the part in the photo it is the same.

Denny

21-05-10 07:59

Yeah I noticed that mate, thanks. Waiting for a delivery quote from the seller now :)

CaptMoto

25-05-10 09:25

Denny I have replied to u yesterday with a final quote from Yamaha uk, all inclusive of VAT it comes to: �116.49 for me to post it insured to Turkey will be another �15 on top of that, so if you want to go ahead let me know.

Denny

25-05-10 10:13

Cheers Capt I got your PM. I'm just awaiting a PM reply from Kev before I give it the all clear.

Thanks
Denny

Kev	25-05-10 11:25

Pm sent mate. I can talk you through the recoding of a new ECU, takes less than 1 min to do. I would also replace the fuel pump relay to be on the safe side.

CaptMoto

29-05-10 16:39

Guess what I've picked up today?

Kev	30-05-10 03:32

O look at that, the correct parts at a quarter of the price. They do look nice & shinny.

Denny

10-06-10 12:12

Result! There was a small box sat on my desk this morning. Fran kindly sent it to a friend in London, who brought it over for me. I am so happy that I will hopefully have a healthy bike again in the near future. Thanks again Fran, you're a top bloke!! The parts are still shiny too Kev :D

Kev, grateful if you could run me through the process of fitting the new ECU and relay.

Out of interest, is there any possiblity that something that was overlooked that could have damaged the ECU? It would be my worse nightmare to have the ECU fail on me once fitted!

Thanks
Denny

Kev	10-06-10 12:45

If all the wiring has been checked then it should be OK.

Key removed, fit new ECU & Fuel pump relay.

Insert Red key in ignition, turn key on wait for the fuel pump to stop, turn key off, remove key.

Within 10 seconds. Insert 1st Black key, turn key on wait for fuel pump to stop, remove key.

Within 10 seconds. Insert 2nd Black key, turn key on wait for fuel pump to stop, remove key.

The keys & immobilizer is now matched. You only use the Black keys to start the bike.

Let us know how you get on.

Denny

10-06-10 12:55

Should the kill switch be on or off?

Side stand up down? (does that make any difference?!)

Kev	10-06-10 13:10

Should be ON otherwise the fuel pump will not run.

Denny

10-06-10 13:21

Ok mate, thanks for that. Hopefully I'll get back to you guys later on tonight with some good news...after I get her running and blow some of the cobwebs off :D

Denny

10-06-10 18:13

Fired up first time :sbike:

Gonna get kitted up now & take her for a blast :D

CaptMoto

10-06-10 19:43

Kev, there's one thing I don't understand, do you have an estimation as to what went wrong with Denny's original ECU, how did it get fried and what is the likelyhood that this can happen to other xt owners? Manhandling, fitting wires incorrectly? Any idea?

Denny

10-06-10 20:15

:family::family::family:

I sure have missed my gal! Just to show how much, I've been out for the past couple of hours burning rubber on my wedding anniversary :005:

Lots of thanks to Fran, Kev, Medo and everyone else for their input and effort...I might be thousands of miles away from all of you but I'm feeling the biker bro love :grouphug5:

medo	10-06-10 22:57

good to hear that your bike is firing again ... wish you many miles of fun this summer :)

Kev	11-06-10 02:07

Quote:

Originally Posted by CaptMoto (Post 130703)

No idea Fran, it is just one of those unknow faults. Will it happen again I hope not. This is the 4th ECU that I know of been change, all 4 have had different problems.

Kev	11-06-10 02:08

Quote:

Originally Posted by Denny (Post 130700)

Fired up first time :sbike:

Gonna get kitted up now & take her for a blast :D

Well done that man. I bet you had a smile when she fired up with no fault code.

Denny

11-06-10 09:02

I can send you the faulty ECU if it can help you find the problem?

Kev	11-06-10 13:18

I have a box full of ECU's at home, 2 which I have paid for & one which was replaced under warranty back in 2006.

The problem is I am still working on a way to reprogram the immoblizer to an old ECU. Once I can do that then I will be able to test what has gone wrong with your XT ECU.

I belong to this forum with these guys doing some great hacks.

http://www.activeboard.com/forum.spark?forumID=99460&p=1

The guys have been working on the MT01 at the moment.

http://www.activeboard.com/forum.spark?aBID=99460&p=3&topicID=23998458&page=1

I am waiting for one of these at the moment.

http://i.ebayimg.com/12/!BrKK5u!!2k~...909I!~~_35.JPG
Yamaha immobilizer emulator.

The emulator of an immobilizer for motorcycles and scooters Yamaha.
Works with all motorcycles and scooters Yamaha from 2006 to 2009.
Does not demand programmingonly need is connect wires.
Completely emulates work of a regular immobilizer, including light-emitting diode work on the instrument panel.

For emulator installation in the case of a regular immobilizer:
1. Remove glue hermetic from the immobilizer case.
2. Take out a PCB from immobilizer and desolder from it wires.
3. Connect the emulator according to drawing more low.
4. Insert the emulator into the immobilizer case.

Colouring of wires and their appointment:
Black (2 pcs.) GND
Red with a green strip BATT (+12v)
Red with a white strip IGN (+12v)
Blue LED (+5v)
Yellow with a blue strip K-line Immo-ECU

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