intermittent faults

[Mr Gee]

Well, swapping the fuses didn't work.   

Back to square one with the electrical fault. Failed again today.     

Can definitely rule out, the clutch switch, side stand switch, start button and kill switch.   

Have swapped them all out with my mates, which is running perfectly.

The hunt continues. 

[Eric GSX1400K3]

Bugger, electrical gremlins are always a challenge.

Don't want to tell you how to suck eggs, but my check list would be:

Battery- try with a known good one, min 12.5V at rest, no less than 10v at cranking speed.

Generator- check for continuity across the windings, you could have a short in the windings that only appears when running

Timing plate, check the captive magnet and connector if thats split or broken, the timing signal gets wonky and she'll stall if broken.

Coil packs, check for resistance, should be about 6k Ohm from the connector to the end that touches the spark plugs, important is that all 4 are the same.

Spark plugs, also check for resistance  they should all be around 6k Ohm. Replace as a set if one reads significantly higher.

All other sensors, check for 5v at the connectors and the appropriate resistance values, however you've already ruled out  the main ones that will cause a stall.

Also, non electrical, but check for false air into the airbox (leans out the mixture too much and it will stall), grey or whitish spark plugs will be a tell tale that its running too lean.

Blocked crankcase breather, blocked or leaking pairs reed valves, vacuum lines or thr clamps connecting the airbox to the tb and to the intakes.

[KiwiCol]

Give a man something to do!!   Geez, Electric bikes don't need any of that . . ..    

[Eric GSX1400K3]

Give a man something to do!!   Geez, Electric bikes don't need any of that . . ..    

except for a one way trip to landfill for all e bikes and scooters

[grog]

So when it stops MrGee, you turn key on, gauges sweep, pump primes?Push button but nothing happens.In that situation what happens if you run a lead to starter, does it turn over?

[Hooli]

My thoughts lean towards a rotten wire in a multi plug somewhere that moves and breaks a connection occasionally. Or a cracked wire in the loom around the headstock.

On the bright side it'll get worse until you can find it 

It would be nice to understand what happens though. When it stops, it's the still 'on' but not running or does everything switch off and no lights, warning lights etc etc

[Mr Gee]

Everything remains on but simply stops running.

Sometimes lasts seconds, sometime minutes.

Sometimes happens repeatedly, sometimes just once.

Does it while at a stand still, does it while going along.

Does it hot and does it cold.

Stationary, moving, wiggling bits deliberately. No one thing seems to any effect.

Guess I just have to wait until whatever it is breaks down completely.

P.S. Battery should have been on the list of things definitely ruled out.

However the rest of Eric's list should keep an electrical ignoramus like me busy for sometime.   

[Eric GSX1400K3]

OK, so if it was a main electrical fault like an earth or battery positive cable,everything would shut down, I.e bike would go dark.

If only engine cutting out, this would mean to me it's spark related, so coils, plugs and leads.

Like Hooli suggested, trimming a few mm off the leads may help. I've done that to mine, just trim  5mm off and screw them back into the plug cap, theres a threaded spike in the top of the plug cap. A dab of silicone once re seated helps to keep moisture out.

I doubt now its pairs, tb balance or sensor related, as none of these will cause engine cut out, just rough running or poor idle.

[Hooli]

Fuel pump relay? I've lost track of what you've tried tbh.

Does it show FI when it stops? Or just look like you've switched the bike on but not started it?

[Mr Gee]

No, no FI light just the ignition light and says check.

Tried it with dealer mode switched on too but no code given. 

[Eric GSX1400K3]

I dare say that once the issue occurs, and the ignition 'cycles', any recorded fault codes would be lost.  Almost need to have dealer plug permanently connected and the fault to happen for you to see what (if any) code is generated.  Fuel pump relay sounds plausible suspect.

[grog]

CHEC means a safety lockout signal not received by ECU.No fault code will be registered   Bad Wiring,or dirty connecter from switches. ECU plug dirty. Clutch switch, kill switch, sidestand & gear position sensor are the inputs.Have heard of gear position switch having dirty contact, can be cleaned. You have tried different kill switch.All others can be measured, readings in manual.

[Eric GSX1400K3]

Good point Grog, from that the only ones not checked by Mr. Gee is the ecu plug and gear position sensor I think, all the others he said checked out.  The ecu plug can be a right pain, all tabs need to click in. I zip tied mine just in case.

[Hooli]

Aye that makes sense chaps, so it cuts out like you'd put the stand down when in gear.

[grog]

Correct Hooli. Fuel stuff, low pressure, blocked filter etc wont throw a code, ECU not that smart. CHEC is for sensors i mentioned, a major clue MrGee. Just like playing cluedo