Hi guys,
Ive just put my bike back together after stripping it for a major freshen up. now when I start it it runs for about 15 seconds then just shuts down all together.(sometimes after 30 odd seconds). the bike has a power commander and is a 2004 model. im pretty sure all the plugs were reconnected correctly and no wires were cut or shorted out.

today it idled for a minute then soon as I went to take off it just died.

one thing is the engine light comes on when I turn the key on but it goes out when its running. then comes back on after it cuts out.

the bike was lying around with all fuel drained for 2 months so Im thinking there could be a problem with the fuel pump.

I tried working out the fault codes and all i could find was the following:
do1: 17
do3: 100
do5: 28
do6: 31
do8: 40
do20: on
do21: on
do62: 1

in the manual I couldnt work out what they actually mean, except for certain values etc.


any comments greatly appreciated!!!!

My brother once had his frame powder coated and once reassembled he had problems with earthing.

He had to go back over all the connections and scrape some of the coating off where the screws and bolts mounted.

Just a thought!

thanks GR, good thought. its really weird but the engine dies soon as the green bar led lights die on the power commander3. im thinking it could be a bad wire where the PC3 leads join the harness as they have used these dodgy quick clips that maybe prone to corrosion. I'ill take the tank off later and go over all plugs etc...

Poor earth +1

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My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Guessing it's the power commander then
I seem to remember a post about pinching a fuel pipe when the tank goes back on
But you seem to have found the problem already

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K+N filter, snorkel removed, homemade kev mod (with his blessing), co raised,
Pipeworx cans, r1 led back light, under tray removed, small indicators, handguards, cnc short levers,

I checked for any pinched wires but cant find any & no pinched fuel line.
I disconected the pc3 and ran the plugs back to original, but still no luck.

bike will fire and run for a few seconds then dies.

the batterys flat but im jump starting it off the car battery so its winding over fine.

all sensors etc are connected correctly.

I totally removed the AIS system. this was blocked off previously with bolts fitted in the lines, but ran fine with it blocked off. Where the air line went into the airbox I blocked it off so no dust could get in the filter box.

the bike has a KNN filter fitted and staintune exhausts. It was running fine before disassembly.

The only thing now is a bad fuel pump or a bad earth/ground wire.

Can anyone advise if there are any earth wires that connect directly to the frame as I cant seem to find any! I traced the earth wires from the battery and the only places they went to are to the starter motor ground (through a mount bolt), and the other direct into the wiring loom. (there is one other ground wire, but it goes into the PC3). Ive worked on many other bikes and usually theres a ground wire connecting to the frame near the coil or near the ECU or starter solenoid. I couldnt seem to find any others but maybe Ive missed something...

thanks for the input guys!