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09/fe 450 electrical problem

Joined Mar 2009
236 Posts | 1+
manchester england
I’ve still got the problem with my bike, one minute it runs and the next it wont, but if there's one thing that’s constant it's the f1 orange light goes out like there’s no power, wont light up when the bike wont start!! ive been right through the whole wiring loom looking for a problem and couldn’t find one, at 1st I thought it was the kill switch when I disconnected it started, so I took it off and it ran fine every time I started it, so I left it for a few days, and just thought I’d fire it up this evening before I go riding tomorrow and bam it's dead, so I flatten the battery, then connect the charger leave it for 30 mins and try the starter again and the light comes on like it would start if there was enough power in the battery and it blew a fuse in the charger, what ever the problem is it's electrical and intermittent
Any suggestions before I have to drive 100 miles to a dealer :-(
Many thanks
 
Ive just taken the plug out again, hoping to see it wet after turning the bike over with the throttle wide open, and its dry'
Ive then looked to see if the plugs sparking, and again it's intermittent as with the fuel pump......so what can break down, that affects the power to the pump and at the spark plug!!!!
I'm about ready to shoot it lol come on guys someone on here has the answer!!
 
I'm beginning to think it might be the crank case sensor (pickup) I can't seem to find a loose wire So I'll have to take it to a dealer to run a scan
 
similar problem on an old BMW years ago had me baffled. Turned out it was a break in a wire. The wire was not crimped, bent, burnt or showed any other evidence of a fault. It was only found by accident when the bike was running with the seat off my mate touched the wires and it stopped. He touched them again it it would go again. We slowly but surely narrowed it down to on wire and roughly where to touch it to make it stop. We stripped back some of the insulation very carefully and we found a wire that was faulty from new (we guess), it was just broken through )but not through the insulation). Wen the seat was on it must have been squeezing the wire in such a way that it made a connection, and when you shifted around it would change that connection.

Pain in the butt to find, simple to fix.
 
Had an auto electrician testing parts of my bike for three hours he says it's a broken wire, he's asked me to take off the loom and let him look at it at work ,he's going to strip it back and go from there, one minute we had everything working, the next it would break down again when, tucking the loom away, honestly this is the most frustrating problem I've ever had :-(
 
Its most likely the harness next to the rear shock that has been nagged at, its a common problem at least here in Sweden.
 
My friend tells me it's not the roll over sensor,however I'm getting a fault code of 5 long flashes:) so come on you tecky's
 
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I missed this post originally as I went Motor Bike riding on the 18th and didn't get home till 21st. Not sure why I didn't see it, I will complain to managment, are you awake Json? :)
Motor bike riding, now that is an idea rather than surfing UHE :lol:

I posted all the codes in this post:
viewtopic.php?f=7&t=12991

4x long, 5x short = Lambda sensor heater circuit
9x short = Manifold absolute pressure sensor
1x long, 3x short = Intake air temperature
1x long, 2x short = Engine coolant temperature sensor
6x short = Throttle position sensor
1x long, 7x short = Lambda sensor
3x long, 3x short = Injector
2x short = Crankshaft position sensor
3x long, 7x short = Ignition coil
1x long, 5x short = Rollover sensor
4x long, 1x short = Fuel pump relay

5 Long is not in there. Let me think when I have sobered up, been on the 2006 Penfolds 389 all night with my 88 year old dad and this is the first time I have seen this post.

I do remember seeing a post from Crazy Ted with a wire worn out in his wiring loom. His was the Fuel Pump wire and it was blowing a fuse. Yours could be another wire causing a problem. Let me think.
Crazyted has a good picture in this post of his loom:
viewtopic.php?f=1&t=12640

Go back to basics:
When your bike does not start can you hear the fuel pump if you just touch the starter for a second or two?
Tight Battery Terminals?
How old is the Battery? Has the Battery been flat a few times, ra ra ra Dirt Bikes, vibrations, batteries don't mix.
Spark Plug OK?
Any unusual circumstances happen right before this occured? Like you dropped it in a river? 8O


johny said:
Ive just taken the plug out again, hoping to see it wet after turning the bike over with the throttle wide open, and its dry'
I don't think winding these new EFI bikes over with the throttle wide open works like a carby. For some reason a slight opening of the throttle then close it again while still winding over works.
I'd chuck a squirt of Areostart down the throttle body if you thought it was a fuel problem.

johny said:
Ive then looked to see if the plugs sparking, and again it's intermittent as with the fuel pump......so what can break down, that affects the power to the pump and at the spark plug!!!!
Can you explain more? What do you mean by "it's intermittent as with the fuel pump"


johny said:
I'm about ready to shoot it lol come on guys someone on here has the answer!!
Don't shoot it.


As far as I can tell, the power to the Fuel Pump, EFI and spark all hapens when the motor starts spining and a set of contacts in the voltage regulator turns on the Power Relay. The Power Relay then turns on power to most fuses.


johny said:
but if there's one thing that’s constant it's the f1 orange light goes out like there’s no power, wont light up when the bike wont start!!
Can you give a more detailed explanation of the FI light going out. Sorry to ask a dumb question but my FI light goes out before the bike starts or just after it starts (can't quite remember exactly when but it goes out) then the 570 hammers, I'm still reminiscing of coming around smooth dirt corners in 5th at about 80Kmh and cracking the throttle and feeling the back wheel spin (yir har)
 
Broken wire near the shock,I've had sooooo much stick from my friends and people on the ktm forum hopefully I'm back in business I love this bike :)
 
I would like to say a big thank you to graham at Midwest for all his advice :)
 

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