• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

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Check engine light weirdness

Chopperbob

Chopperbob

Husqvarna
AA Class
So I have about 12k miles on the Strada. I had an independent mechanic do the valve inspection at 6-7k miles. He could not turn off the "wrench/spanner" service icon on the dashboard. Now, while riding at various speeds, the yellow engine light turns on and suddenly a rev limiter "bump" type of a feeling comes with it briefly, as the rpm's reduce, and then the engine continues to run, albeit with the yellow engine light illuminated.

If I close the throttle for about 10 seconds, the light disappears and the bike runs normally again.

I'm taking the bike in to have the mechanic check it, but I thought I'd ask if anyone has experienced this sort of behavior on the TR-650 or any other bike?

Safe travels!
 
Under the headlight cowling above the headlamp you will see a metal bar that goes from side to side. There is a male/female connector zip tied to the back side of it. Check to see that this plug is completely plugged in. Several of us have found it loose and had the same symptoms. Push the plug halves together if they are loose and the error light disappears for good.

It always happens at idle or even sitting with the key on. Sometimes you can turn the key off and back on and it will clear. This is a symptom of the plug being loose.
 
drzcharlie said:
Under the headlight cowling above the headlamp you will see a metal bar that goes from side to side. There is a male/female connector zip tied to the back side of it. Check to see that this plug is completely plugged in. Several of us have found it loose and had the same symptoms. Push the plug halves together if they are loose and the error light disappears for good.

It always happens at idle or even sitting with the key on. Sometimes you can turn the key off and back on and it will clear. This is a symptom of the plug being loose.
Click to expand...

Gracias!
 
I went through this exact bike behaviour a couple of weeks ago. It got progressively worse.

I ended up doing a couple of things so I can't say exactly what fixed the problem. However... Start with removing the ball bearing in the fuel tank cap vent. This is very quick & easy. Change the spark plugs if they're ageing. I suspect it was either of these two actions that fixed the problem.

I also cleaned the injector, but this was more a matter of 'just in case' and I don't think a fouled injector was the cause of the stutter. I cleaned out a heap of connectors with contact cleaner spray but my bike was in bits, so I thought 'why not?'.

The service indicator icon will stay there until the bike is hooked up to the moss computer. Don't worry about it.
 
drzcharlie said:
Under the headlight cowling above the headlamp you will see a metal bar that goes from side to side. There is a male/female connector zip tied to the back side of it. Check to see that this plug is completely plugged in. Several of us have found it loose and had the same symptoms. Push the plug halves together if they are loose and the error light disappears for good.

It always happens at idle or even sitting with the key on. Sometimes you can turn the key off and back on and it will clear. This is a symptom of the plug being loose.
Click to expand...


Good one Charlie
 
UPDATE: Well, the mechanic and I went through the suggested procedures (Thanks to all who commented) and still no relief. The bike still makes a redline "bump" feel and then the yellow "check engine light" comes on. At different speeds and different RPMS. I can "clear" the light by simply rolling off the throttle, but then sometimes the engine cuts out, which is a real pain.

UPDATE 01Jun15: I did the ECU reset. The bike seemed to run better. BUT... the check engine light and "rev-limiter type stumble" still came on several times the first day. However, yesterday, I rode about 50 miles at speeds up to 75 mph and viola!...no light or stumble. I'm keeping my fingers crossed and I still have an appointment with the dealer next week, just to have the bike hooked up to see what this madness was. When I rode the bike to dealer, unfortunately I experienced the "rev-limiter" bump several times on the 65 mile trip.
 
UPDATE: 11June15- (My bike has been in the shop for over one week) I was contacted by Motoforza, the Husky dealer in Escondido, Calif. and they located the fault throwing the "Check Engine" light and producing the "rev-limiter" like bump I feel during rides. My bike apparently has a faulty "crankcase sensor" which costs $1,300.00 USD and is 2-3 weeks away in Austria. Of course my bike is out of warranty, with over 12,000 miles. So the Service Manager is trying to get ahold of the Husky rep to see if Husky might cover this for me. They have never come across this problem before in ANY type of bike they service.

So I'd like to ask some advice. If Husky does not cover this repair, does anyone know if the sensor can be left disconnected and will the bike run normally, without it connected?

Thanks in advance for any help or advice, Bob
 
Chopperbob said:
UPDATE: 11June15- (My bike has been in the shop for over one week) I was contacted by Motoforza, the Husky dealer in Escondido, Calif. and they located the fault throwing the "Check Engine" light and producing the "rev-limiter" like bump I feel during rides. My bike apparently has a faulty "crankcase sensor" which costs $1,300.00 USD and is 2-3 weeks away in Austria. Of course my bike is out of warranty, with over 12,000 miles. So the Service Manager is trying to get ahold of the Husky rep to see if Husky might cover this for me. They have never come across this problem before in ANY type of bike they service.

So I'd like to ask some advice. If Husky does not cover this repair, does anyone know if the sensor can be left disconnected and will the bike run normally, without it connected?

Thanks in advance for any help or advice, Bob
Click to expand...

If you have access to a GS911 unit, you might be able to clear the "fault code", without any other expense
Then carefully work thru' all the wiring connections, l use a squirt of Lanolin to improve & weather protect every connection
 
If I remember correctly someone had an issue with a faulty flywheel. Without looking at it more in depth I'd guess this crankcase sensor is the equivalent of a crankshaft position sensor that reads off the flywheel.

Remember that despite popular conception the answer is not always pointed out by the fault code. It has to do with the electrical circuit. The ECM may be seeing an erratic crankshaft position sensor and that will certainly cause the stumble (or rev limiter effect). This will typically set a code for that sensor. This can be the wiring, sensor or the component the sensor is reading(flywheel).

Also $1300 is an amazingly high price for this type of repair unless they are in fact replacing the flywheel. If that's the case I really haven't a clue on what it should cost.
 
Sorry for the delay in a response. Thanks to all who suggested a cheaper fix. I will definitely try some of these if Husky does not come through with a gratis repair. Tomorrow will be 2 weeks since I brought the bike in for service.
 
Well KTM totally threw me under the bus. They won't fix the bike or any other good will gesture. Motoforza, the dealer, is trying to get the crankcase sensor at a reduced price from Halls because they bought some TR-650s for parts. Many people have commented that they do not see a sensor that costs $1,300.00 on the fiche. I'm not sure how to verify that this fix should cost this much.
 
Chopperbob said:
So I have about 12k miles on the Strada. I had an independent mechanic do the valve inspection at 6-7k miles. He could not turn off the "wrench/spanner" service icon on the dashboard. Now, while riding at various speeds, the yellow engine light turns on and suddenly a rev limiter "bump" type of a feeling comes with it briefly, as the rpm's reduce, and then the engine continues to run, albeit with the yellow engine light illuminated.

If I close the throttle for about 10 seconds, the light disappears and the bike runs normally again.

I'm taking the bike in to have the mechanic check it, but I thought I'd ask if anyone has experienced this sort of behavior on the TR-650 or any other bike?

Safe travels!
Click to expand...

Did the mechanic have a MOSS or OSS tool...? This spanner is removed when the service interval is reset, the light may show up as fault on a MOSS Tool.

Is this the sensor part #3? http://shop.italhusky.com/en/products/2013/tr-650-terra-and-tr-650-strada/engine-electric-system--5

At Euro 710.33, BMW are butt rapists!
 
I will have to reply sometime tomorrow when the shop is open, to get the specifics on the part number.

I will update you all on the exact part number when I find this information out. This whole problem WAS diagnosed by their MOSS tool, which had just been updated last month when the KTM Pres.-USA visited their shop and was told the MOSS tool was woefully out of date.
 
From my reading, only 2 pieces are sold as item 1 for Euro 516.84. Not all the pieces and certainly does not include the sensor.
 
This is what I got today as a reply from the Service Center. They will not let me return the BMW part IF it does not fit:
"Husky part number for the crank sensor is 7652904. Husky catalog currently shows its $999.99 and OUT OF STOCK. We spoke with the husky parts guy in Ohio last week and he had stated its $1300 and would be available in 3-4 weeks. I had Kris check the BMW parts breakdown for the GS 650 and the crank sensor there is $240. I cannot say for certain that it will work."
 
Ogre_fl said:
FWIW The crank position sensor/pulse generator appears to be a cross over part with the BMW GS.
Should be $241 new, possibly available used.

BMW PN 12117652904
Husky PN 7652904

http://parts.bmwmotorcycles.com/p/BMW__/Pulse-generator/42779836/12117652904.html
Click to expand...

OGRE, you're the winner, you found the Husky part AND the BMW part they are considering. I will take the plunge on the BMW part, just because I'm cheap that way. Here's hoping that the pins/plug are identical...
 
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