SOLVED: XT660ZA 2015 won't rev above 5.5k RPM when hot..
 

Hello all,

Synopsis:
My XT660ZA (ABS, 2015) won't rev above 5.5k RPM, when the water temperature is above 107 �C (225 �F). When I try to rev it up, the "Engine" (yellow light) and "Temperature" (red light) flash momentarily, my throttle cuts off and my headlight dims for a split second. After dropping the RPMs, the throttle resumes.
Any ideas, what is the problem?

http://images.mcn.bauercdn.com/uploa...t660z-tene.jpg

Full story:

I own a XT660ZA (ABS model, 2015), and I was doing 110+ kmh, on 4th gear, with the RPM up to 5500+, when suddenly the "CHECK ENGINE" and the "WATER TEMPERATURE" lights blinked for a second, my throttle was cut down momentarily but resumed after 1 sec. At first i though it might be the REV LIMITER and started asking around ( previous thread).

Since I also considered 5.5k RPM as a very low rev for Limiter, I had the bike checked on the YAMAHA authorized Dealer/Workshop where I bought it from.
We did the diagnostics test via the diagnostic port of the XTZ, but found no error code, except a "lean angle" problem (code 41), which was expected because I was had the sensor removed to rearrange some cable routing.
While trying to reenact the problem, we found out that the problem appeared only if the radiator water was above 107 �C (225 �F). When reving up from cold, everything worked fine.

This is the same temperature the radiator FAN kicks in. We disconnected the FAN, in case it was a FAN-problem, but the problem still occurred, thus eliminating the FAN as a cause of it. FAN: OK.

Then we checked the RECTIFIER, while running the engine, which outputted above 14.2V, so it was ok too. When the REV-cut-off was reproduced, the voltage stayed pretty much stable at ~14V, without any voltage drop. So RECTIFIER: OK.

We did a thorough inspection of the fuses, which found no fuses blown, so all these were OK: Main, Parking Light, Signaling System, Headlight, Ignition, Fuel Injection, Radiator Fan, ABS motor, ABS solenoid, ABS control unit. So FUSES: OK.

I am running the bike, pretty much stock, with only external spotlights and 12V power socket, and heated grips. All these are powered via a fused cable from the battery, which was disconnected when testing, so AUX POWER: OK.

IT HAS BEEN A STRENUOUS TEST and any help would be deeply appreciated!
Thank you!

No ideas, anyone?:hb:

Clutching at straws here, but you say the problem only happens when the fan kicks in. I know you disconnected the fan etc. but where abouts? Before or after the relay? Did you pull the plug to the fan or pull the fuse? Perhaps pull the fuse and then test, careful not to overheat the bike of course.

I know on my XTX everything starts to get a bit vibratey around 5,500rpm... maybe there's a damaged/rubbing wire and vibrations are disturbing it, maybe shorting on the frame?

We did that. There seams to be no problem from the fan/fan cable...

That is our focus now... Let's see..

THANK YOU!

SOLVED!

It seems like the problem was a contact-fault of a pin on the plug which is located on the right side of the, near the radiator, free-hanging.
We repressed the pins on the contacts with pliers and the problems seems to be fixed...
We will see :)

Good find - well done! Which plug was it, out of interest?

On the manual, I could not locate the connection. But these are the photos from the bike.

From the RIGHT side of the bike.
http://i67.tinypic.com/21o3eqt.jpg

It is this one.
http://i67.tinypic.com/11via9f.jpg

Any ideas which one is it?

Hi. I am new member of the forum, my mount is a Tenere of the year 2013. I happen something similar, when the bike is hot, when I start it and make the initial check, the engine failure light goes out and the temperature light a second and it goes off, it only does it sometimes. It does not affect the operation. I have cleaned the connector of the photo in case it could be the same fault. A greeting.

Interesting. Though I'm afraid I don't recognise that connector (I have an XTX). Must be a Tenere thing!