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Urgent help!

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Post  Cardboard Tube Samurai Wed 27 Apr 2016, 7:31 am

First topic message reminder :

I did my plugs and filter over the weekend, so had the tank mostly off (left the fuel hose attached as it was long enough to maneuver the tank around still). Got to work this morning and have noticed a couple of drops of clutch or brake fluid dripping from one of the drain hoses. Could I have possibly loosened something while I had the tank off? What should I be looking for? I'm 74km from my tools so I'm hoping it's a slow enough leak that I can make it home and fix it tonight
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Post  Cardboard Tube Samurai Tue 03 May 2016, 10:34 pm

Yeah I've checked the connection there and it seems to be okay. Just a very strange coincidence that the ECT would go as soon as I've done the plugs and filter  scratch
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Post  Bosco15 Tue 03 May 2016, 10:49 pm

Quite strange.  
It says in the manual to be careful with the ect sensor.  It can be damaged if knocked.  
You can test the resistance if you have a multimeter.
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Post  Bosco15 Tue 03 May 2016, 10:54 pm

You should read somewhere between 2000 & 2450 ohms at room temperature. 25c -20c
If you read something very different, then I would say sensor is stuffed.

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Post  Cardboard Tube Samurai Wed 04 May 2016, 9:23 am

Sensor and o-ring ordered. $75 later, hopefully it should be fixed tomorrow night
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Post  Chook Wed 04 May 2016, 9:41 am

Cardboard Tube Samurai wrote:Sensor and o-ring ordered. $75 later, hopefully it should be fixed tomorrow night


What readings did you get CTS?
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Post  Cardboard Tube Samurai Wed 04 May 2016, 9:51 am

Didn't have a chance to check it. Just running with the theory that if I've ruled out everything else, it's probably a dead sensor
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Post  Cardboard Tube Samurai Wed 04 May 2016, 9:52 am

I'll check it tonight to confirm though
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Post  Cardboard Tube Samurai Sun 08 May 2016, 4:45 pm

How the bloody hell are you supposed to get multi meter leads onto the terminals of the ECT sensor!?!?!? Bordering on impossible. 

In an interesting turn of events, I took the missus out for a ride the other night and when we pulled up at our mid trip destination the fan was working, just as it should have been. Turned the ignition on and off a few times to make sure I wasn't dreaming. Now, it's not working again. So this brings me to wondering if it's possibly a sticky relay that only seems to want to work intermittently. I let the bike idle up to temp today and the fan didn't engage. Put a finger on the relay to feel for a switch but it didn't (can definitely feel the switch on the fuel pump relay when ignition is turned on). 

Another possibility I thought of, which came about from reading of other people with a similar problem, is a potentially loose or broken wire in the ECU loom. If the extra weight on the back of the seat made things sit slightly differently, this could have helped the fan work...?  scratch

Any ideas?
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Post  Bosco15 Sun 08 May 2016, 5:44 pm

Relays do burn and get sticky. Very cheap to replace. I would do so.

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Post  Cardboard Tube Samurai Sun 08 May 2016, 6:06 pm

That's what I'm thinking. Around $50 from memory, so not all that "cheap", but certainly easier to swap out. Problem is, I'll be stuck with the ECT sensor. There's always eBay I guess
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Post  barry_mcki Sun 08 May 2016, 7:29 pm

CTS, are you expecting the fan to kick in as soon as the bike is up at running temperature ?

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Post  Cardboard Tube Samurai Sun 08 May 2016, 7:48 pm

No, but I'd expect to see it come on by the time coolant starts coming out of the overflow
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Post  Bosco15 Sun 08 May 2016, 9:31 pm

Cardboard Tube Samurai wrote:That's what I'm thinking. Around $50 from memory, so not all that "cheap", but certainly easier to swap out. Problem is, I'll be stuck with the ECT sensor. There's always eBay I guess

I would be thinking more like $15 or so for a relay. You don't have to go genuine Suzuki. 
You should be able to return ECT for credit too, I would imagine.

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Post  Cardboard Tube Samurai Mon 09 May 2016, 7:08 am

Any suggestions on where to get the relay? I'm just going through my local (not so local) bike shop. Googling was no help
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Post  madmax Mon 09 May 2016, 7:55 am

Cardboard Tube Samurai wrote:Any suggestions on where to get the relay? I'm just going through my local (not so local) bike shop. Googling was no help

If your just referring to a normal 12v 30amp relay you can get them at any auto parts store

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Post  Bosco15 Mon 09 May 2016, 10:50 am

It will be one of the better known electronic auto parts manufacturer,  probably Denso, so should have a part number printed on it. 
Ashdown Ingram or someone similar,  auto electric supply will have them.

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Post  Cardboard Tube Samurai Mon 09 May 2016, 12:03 pm

Omron G8MS-S23. I work about 100m from an Ashdown Ingram branch so might just pop 'round there. Thanks!
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Post  Cardboard Tube Samurai Mon 09 May 2016, 12:22 pm

$16, 41 of them in stock. I'll swing by on my way home.   Cool
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Post  barry_mcki Mon 09 May 2016, 1:07 pm

I've found this circuit diagram easier to read than the full version, also I have added some colour to a couple of lines to help understand what has power and when.  

The fan relay up in the top right is pretty generic, has fused (#6) power (red line) to one contact with the other side going to the fan (orange), and power to one side of the windings (yellow) with the other side getting and earth from pin 15 of the ECU.  The ECT Sensor puts a variable voltage to pin 10 of the ECU, depending on what that signal is the ECU will put out an earth on pin 15.

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If you suspect a sticky relay, to test it look for the earth being applied via pin 15, you should see +12v on both sides of the relay windings when below temp, and then the pin 15 side should go to 0v when activated by the ECU, thus energising the relay and applying the fused 12v out to the fan.

I'm wondering if you applied a heat gun to the ECT sensor at the bottom of the radiator to warm it up (careful not to melt anything in the process) if you can get it to trigger the ECU.  You shouldn't need the bike running, just the ignition on to do this test, just don't leave it too long in the ignition on/not running condition, I'd say no longer than 30 seconds. You might be able to simulate the coolant getting hot and triggering that earth on pin 15.


Last edited by barry_mcki on Mon 09 May 2016, 1:09 pm; edited 1 time in total

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Post  Bosco15 Mon 09 May 2016, 1:08 pm

Sweet result.  Very Happy

Pull the old one appart and check the contacts.

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Post  Cardboard Tube Samurai Mon 09 May 2016, 2:16 pm

Thanks Barry. If the relay swapout doesn't fix it, I'll be delving further into the wiring to find the gremlin. That's a much more user friendly wiring diagram than others I've seen
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Post  Cardboard Tube Samurai Mon 09 May 2016, 6:33 pm

Swapped in the new relay. I left it running for a couple of minutes after getting home from my 1hr commute. Fan didn't kick in and it started to dump coolant. Grrrr! Mad
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Post  Bosco15 Mon 09 May 2016, 10:15 pm

Bugger! 
Time to start investigating all the connections for continuity.

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Post  Cardboard Tube Samurai Tue 10 May 2016, 10:25 am

I'll need to drop some coolant to change out the ECT sensor, right?
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Post  Bosco15 Tue 10 May 2016, 1:12 pm

Urgent help! - Page 3 Screen14[url=https://servimg.com/view/18651528/169]Urgent help! - Page 3 Screen14[/url]

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