The servo moved intially; with the TPS unplugged and ign on it swept to down (towards LO). I then started the bike and gave it a little bit of throttle and the display immediately flashed ERR2, I turned IGN off instantly half expecting a problem and not wanting to burn the PGM out.
When I turned the bike on again the ERR2 was gone (not like on my previous PGM where it stayed on constantly when the servo was hooked up to the loom) but when I kick start the bike and rev again ERR2 comes back.
Has anyone got any idea what could be the problem? I'm trawling the site now for similiar issues.
I put the old PGM on and it gets a constant ERR2 message from the moment the card goes in which suggests to me that the RC valve electronics are stuffed/burnt out.
With the new PGM there is no ERR2 message when the card is inserted, no ERR2 message when the IGN is on...it only comes on after about 30 seconds of the bike idling (I swiftly turn the bike off then).
The servo hasn't moved from the first time I plugged the new PGM in and then it only moved very slightly towards the LO position.
I've got a feeling the servo is fooked and have already ordered a new one.
Hi man, yup..changed the servo...i have the same problem & was thinking it was the servo...i bought it new cost me $300..
Then fix my new pgm unit & it start to move...
Hi Joeking, did u managed to redo yr CDI unit at Mr Morawaki Man?
Have you checked that the RC Valves move freely without the cables attached?
If the RC Valves have built up carbon deposits, they will start to get jammed, causing the servo to overload trying to turn to move the cables, to move the pulley's to move the rc valves. that is when the PGM will get overloaded and burn out.
Pull the cables off the pulleys on the RC Valves and check your valves.
mighty max wrote:Hi man, yup..changed the servo...i have the same problem & was thinking it was the servo...i bought it new cost me $300..
Then fix my new pgm unit & it start to move...
Hi Joeking, did u managed to redo yr CDI unit at Mr Morawaki Man?
I had my CDI sent to someone else but it came back with the same problem. Got a new servo on order.
Have you checked that the RC Valves move freely without the cables attached?
If the RC Valves have built up carbon deposits, they will start to get jammed, causing the servo to overload trying to turn to move the cables, to move the pulley's to move the rc valves. that is when the PGM will get overloaded and burn out.
Pull the cables off the pulleys on the RC Valves and check your valves.
Hi Charles,
With the cables off the pulleys move very easily, no stiffness at all. With the cables on I can turn the servo pulley by hand and the valves move or I can move the pulleys by hand and the servo pulley moves. I had the pipes off the last week so I inspected & cleaned the whole area.
If I'm not mistaken moving the pulleys (on the barrel) by hand anti clockwise should open the valves (be fully recessed into the barell) and obviously clockwise will close them (blocking the exhaust port)?
What I noticed earlier is that when the servo did move it swept to the LO position (to indicate the valves are closed/blocking the port) but it moved the pulleys on the barrel clockwise (opening the port). Maybe the cables have been installed incorrectly?
Either way at the moment I have the cables completely disconnected from the servo and still when kick starting the bike the ERR2 message comes up after a while and there is zero movement from the servo.I think the last owner has had the servo apart at some stage and it's either been reassembled incorrectly or been fooked.
yet, sounds like your heading in the right direction with the cables on backwards, or possible the servo motor itself. If it had been taken apart, I would suspect it, or possible the connector to the servo (wired been reversed) providing power to the wrong terminals on the servo motor, making it run in reverse?
Hopefully the manual will help you out. It looks like a delivery attempt was made today (got an automated email from USPS about the delivery), so you should have it very soon, if not already!
I'll switch the cables over tomorrow, should be as simple as swapping the top set of cables with the bottom set on the servo pulley. Or it could be that the pulley is on upside down.
Do you know if the servo spindle is 360 deg. movement? Or if it swings automatically between two fixed positions (HI & LO)? If the servo has been taken apart and re-assembled incorrectly it could be that the HI/LO positions are completely out of sync now. Not sure if that makes sense!
Can't wait to get my hands on the manual No attempted delivery today but it's probably Dubai's backward system. When items get shipped here they end up in a central post office, they never get delivered by the post office, they just sit there until you call or pop in with the tracking number...I'll head down tomorrow morning.
if my memory is correct, the servo does not go 360 degrees, it's limited in it's movement.
Once you get the manual, go to page 19-13, that is where the RC Valve Servo Motor inspection starts. Has 2 pages in trouble shooting/checking for proper operation of the motor and wire harness.
yet, sounds like your heading in the right direction with the cables on backwards, or possible the servo motor itself. If it had been taken apart, I would suspect it, or possible the connector to the servo (wired been reversed) providing power to the wrong terminals on the servo motor, making it run in reverse?
Hopefully the manual will help you out. It looks like a delivery attempt was made today (got an automated email from USPS about the delivery), so you should have it very soon, if not already!
Charles you're a genius, that manual is a god send Lots of troubleshooting help in there for the ERR2 message, much more help than I thought or could find through posts on here. Really is top class work you've done.
Should have bought this manual two months ago, would have saved me so much time. Carried out two of the ERR2 troubleshooting tests and I think I have found the problem.
Step one was to check the voltage on the 4 pin servo connector on the loom with the servo unplugged, PGM card in place (reading should be above 4.5v). Reading was 5v on the Y/R & BU/G connections, sorted.
Step two was to check the voltage from the servo motor, servo plugged in, PGM card in place. Reading was less than 2v on the ltG & BU/G connection...
Now the manual says that an abnormal reading at step two means the RC valve motor is defective. I'm assuming that normal is above 4.5v as per step one and that my RC valve motor is goonered, or there is a dodgy connection somewhere...
I did a continuity test with the servo motor plugged into the loom and the PGM unit unplugged.
As per the manual I checked continuity on the W & W/R connections (the servo motor wires) on the white 16 pin connector, my PVM made a noise so fine there.
Next I checked continuity on the BU/G & Y/R connections (the servo potentiometer wires I think, from looking at the wiring diagram and also linked to the TPS...) on the black 16 pin connector...no noise from the DVM, just the infinity sign.
The manual states that the infinity sign is abnormal and in that case the RC valve servo motor connections are faulty or there is a broken wire in the harness, normal readings would indicate a fried PGM.
Now, my question is what is exactly is my problem here? lol. I've had what seems like a case of Red Bull and feel like I've been typing for several hours, it's also almost 2am and I cannot focus at all...the answer is probably staring me in the face I think the servo motor potentiometer is pooped
joeking78 wrote:
I did a continuity test with the servo motor plugged into the loom and the PGM unit unplugged.
Joe, unplug the servo motor as well and check for continuity among the fitments.
There are four wires on the servo fitment and a separated Lt/Gr and they all end up on the 16pin connectors of the PGM unit.
This will verify if there is a broken and/ or a loose wire at your wiring loom.
You should also unplug the cables from the servo mechanism. If there is a problem, you will risk less to fry the PGM units -if they are still in working condition-. Just let the cables on the exhaust valves and unplug them from the servo mechanism.
Regarding the servo motor.
With the servo unplugged, position the pulley halfway, between "Lo" & "Hi" positions.
Set your multimeter for resistance measurements and check blu/G and lg wires & lg and Y/R wires.
You should read about 2.5Kohm on both readings. _________________ 2t-racelab.com
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