Bike was parked May-Oct this yr. Poured in tank fuel stabilizer gasoline formula to "keep the fuel fresh during storage, prevent resin build-up & corrosion..." (friend's advice). Oct came so did maintenance and mods: Engine Oil & Filter, Brake Fluid, Galfer ABS bypass brake lines (plugged abs with some bolts), Woodcraft GP shift conversion, changed handlebar grips, new tires and brake pads. Took it to the track and then this happened:
Few min after warm up, engine sounds choppy and slow/retarded. Sluggish throttle response far from crisp. A minute later theres a major loss of power and now sounds like only 2 cylinders are working. Bike becomes a struggle to cruise with. Check Engine Light pops up. Then engine shuts off on its own.
Turned bike off/on and now it immediately jumps to 2 cylinders working and shuts off. Disconnected/reconnected battery did the same. Tried again only held the throttle open a little to avoid it from shutting off and then when I let off the throttle the bike was still revving for a good couple seconds (as if my hand held it at a certain rpm range)
. It was long enough for a spectator in the pits to raise his eyebrows in shock.
Used DealerTool found fault code P0203- Injector 3, Circuit malfunction (pic attached). Cleared code. Started again and it sounded fine. Moments later its back again. Mechanic cleaned injectors to flow equally. One was slightly dirty but far from blocked. Injectors filters replaced. Fault repeated. Swapped the injector connections bypassing the bazzaz zfi-TC unit and said the problem was the bazzaz. Engine runs fine without the bazzaz (for a few minutes we didnt try it for much longer). Reconnected bazzaz looked at bazzaz light and it was on. Moved some wires and light stayed on. Checked wires and everything well connected no broken pins no issues. Checked fuel line not bent. As the mechanic attempted to swapped from bazzaz to OEM connections I noticed that every time he lifted up the tank the check engine light immediately came on and engine shuts off and would barely/not want to start.
Took off the tank, emptied fuel was noticeably dirty. Pulled out pump also dirty. Fuel pump filter was very dirty. Cleaned everything as best we could and looked noticeably better. Theres another filter inside the pump unit that could not be removed for cleaning but we tried to flush it clean (using petrol of course) air pressured everything dry. Removed the tank fuel level sensor unit cleaned and checked it with a voltage meter read fine (although I dont know why my fuel level gauge never works til I start riding). Reinstalled everything. This took about an hour. Cleared all fault codes and this time we started with the bazzaz zfi tc connected. Engine sounded great! Throttle was shockingly crisp and almost felt like I could control it within ~50 rpms and theres 0 lag
. Mechanic was confident to put bike together and take it home. I insisted we leave it running for 30 min. After 25 minutes, the engine shuts off. CEL back with the same code. Engine sounds awful. Horrible throttle control. Same issue repeats
Stuff that I have as spares
that I could replace/use during troubleshooting:
Bazzaz ZFI (no TC)
Kemso Fuel pump 13802 and filters.
1- What happened during those 25 minutes that changed everything from perfection?
2- 30min runtime each time is taking too long to repeat over and over, anyway to shorten this?
3- Is the kemso fuel pump good? (previous owner passed it to me.. and said dont use
4- What is the correct sequence of events to tackle this and isolate the problem?
5- If the same "injector 3 circuit malfunction" reoccurs could it possibly be anything besides the injector?
6- someone (i have issues trusting) mentioned, I would need to replace the full harness to compliment the abs bypass brake lines and that is the reason Im having issues. Could he be right?
7- What would be a clear indicator that bazzaz is the problem?
8- Are these bikes notorious for faulty injectors?
As of now my plan of action is:
1- Swap injector 3 with injector 1
2- bypass bazzaz injector connections with oem.
dunno what else. Any tips appreciated.