My 2009 GTR has 69500 miles on it and it seems that both the Keypass ECU and the main ECU have burnt out.
Along with the Regulator Rectifier which then cooked and melted the battery casing!
Has anyone had to replace the ECUs and if so where is a good place to source them.
The dealership has suggested I might save some money by trying to find a crash damaged GTR to get second hand ones - but I don't particularly want to buy into more possible problems in the future.
Anyone got any ideas.
If you want to buy Kawasaki OEM Parts New, then you will find it all here for the A9F
http://www.kawasakioriginalparts.com/kawasaki_motorcycle_parts_block_selection_M30.php?mod_01=99912-1486&year01=2009&ca=GB
There is one on ebay..
http://www.ebay.co.uk/itm/like/141110339328?limghlpsr=true&hlpv=2&ops=true&viphx=1&hlpht=true&lpid=108&device=c&adtype=pla&crdt=0&ff3=1&ff11=ICEP3.0.0&ff12=67&ff13=80&ff14=108
Have never heard of this issue before..
I killed a regulator/rectifier which took out the main fuse. But the ECU lived.
The reg/rec was full of mud which didn't allow it to cool so it was probably my fault :hammer:
I'd say you'd get another 69,000 miles from a second hand unit.....
Whereabouts is the regulator/rectifier on the bike?
Quote from: Kwikasfuki on July 10, 2014, 03:27:49 PM
Whereabouts is the regulator/rectifier on the bike?
Underneath, above / bit forward of back wheel.
Quote from: Déborah on July 09, 2014, 10:48:00 PM
If you want to buy Kawasaki OEM Parts New, then you will find it all here for the A9F
http://www.kawasakioriginalparts.com/kawasaki_motorcycle_parts_block_selection_M30.php?mod_01=99912-1486&year01=2009&ca=GB
There is one on ebay..
http://www.ebay.co.uk/itm/like/141110339328?limghlpsr=true&hlpv=2&ops=true&viphx=1&hlpht=true&lpid=108&device=c&adtype=pla&crdt=0&ff3=1&ff11=ICEP3.0.0&ff12=67&ff13=80&ff14=108
Thanks for that. I'll check on there now.
This will be the third rectifier when it's fitted. But the two ECUs are around £700-900 each, plus VAT!!!
The joys of biking.
If this is all the result of the regulator failing, then overvoltage killed the ECUs, it must be worth thinking about fitting a "crow bar" type over voltage protection across the battery.
Richard
Quote from: Richard on July 10, 2014, 07:59:23 PM
If this is all the result of the regulator failing, then overvoltage killed the ECUs, it must be worth thinking about fitting a "crow bar" type over voltage protection across the battery.
Richard
Thanks Rchard.
The bike is in South Wales Superbikes in Newport so I will mention this to them.
They were puzzled as to why the one should affect the other. They rang Kawasaki and they were puzzled as to why it should keep blowing the fuse when the regulator was connected again, as they are on different wiring systems.
It seems that the failing rectifier cooked (and melted) the battery, which also fed mega power to the ECU but that doesn't explain why the Kipass unit also went.
If I'd have had a 'crow bar' when it broke down the bike would be in bits in the river Taff by now.
Deborah, thanks for the eBay link. I've ordered that unit and I've sourced some other bits that I need from a different supplier. I guess it's times like this that having a trade discount account comes in handy.
It's just the 'big' bit left to get (the £1000 bit!!)
But things are looking brighter, thanks chums.
Quote from: Foody on July 10, 2014, 08:34:06 PM
Deborah, thanks for the eBay link. I've ordered that unit and I've sourced some other bits that I need from a different supplier. I guess it's times like this that having a trade discount account comes in handy.
Glad I could help in some way..
Also save that other link I sent you re: A9F parts.. Its good to work out the cost of parts when needed.
Still Bikeless over this problem. (it's a long story - 1 fault found, leads to another....)
After fitting a new replacement Kipass ECU that one also burnt out. Neither the original or the replacement could be repaired.
So I am looking for anyone who may have a damaged or breaking GTR that may have a salvageable Kipass ECU. To be able to seel the unit.
I've tried eBay etc but no luck.
The alternative is to buy another new one (£700 - 800).
The fact that there doesn't seem to be many 'scrapped' GTRs may be a testament to the quality of the bikes, and/or their riders, but it doesn't help me much!
A High Mileage Problem??
After all the problems I had with my GTR. It's currently got 72,000 miles on it. The source of the problem seems to be some 'crimped' wiring under the fuel tank which was short circuiting.
Over time this caused the power surge which burnt out the rectifier, melted the battery, and burnt out the main ECU and the Kipass ECU. (a bit of a major meltdown! - Expensive too)
The dealer who spoke to Kawasaki UK hinted that this may be a problem in higher mileage bikes as the wiring under the tank can become crimped and worn.
Last week I was speaking to another bike instructor in Swansea who has a GTR with similar mileage (high 60,000s) and he said his bike is off the road suffering similar symptoms, with a burnt out rectifier and ECU. He is going to get his wiring checked to see if it's a similar cause.
So this maybe something worth bearing in mind if your bike is getting on a bit, or if the tank is on and off a few times for whatever reason.
Mine is back on the road and I still love it. Still cheaper to maintain than my wife!
Where were the wires crimped?
:agree: we need to know exactly where so we can take preventative measures.
Also I am going to sus out the simplest way to fit a crow bar over voltage safety unit.
Richard
Blimey foody, it sounds like your loom suffered in the same sort of area as mine, but probably a different wire was faulty. Gutted to hear of all your problems, and easy with hindsight, but I do think that after such a failure the garage should've checked for wiring faults sooner. I certainly would have checked as much of it as I could before fitting new units. Can't you ask them to come to the party and at least reduce the labour bill?
I know you don't want to take the tank off again, but some pictures of where you have problems would be good please.....
Thanks
Neil
I'll try to remember how to load the pictures up and post the pics I took of my loom
(http://i790.photobucket.com/albums/yy182/markh147/IMG_20141011_194859_zps9f587748.jpg) (http://s790.photobucket.com/user/markh147/media/IMG_20141011_194859_zps9f587748.jpg.html)
(http://i790.photobucket.com/albums/yy182/markh147/IMG_20141011_195221_zpsdbc5ff12.jpg) (http://s790.photobucket.com/user/markh147/media/IMG_20141011_195221_zpsdbc5ff12.jpg.html)
There you go Neil, hope that gives you an idea.
The blue bits of tape you can see are all covering joints in the loom. I think I found between 10 - 15 joints in that section of loom alone. To be fair, all were clean apart from the faulty one in picture 2. I re-soldered all the joints as a precaution. I found two small holes in the under tray, which were allowing dirt, grit and water to be sprayed up under the tank from the wheel. This caused the corrosion to the tank and a small section of the loom. A hugger may have prevented the problem. I guess this is the area where Foody had the problem as well?
Mark
Quote from: shaggs147 on October 27, 2014, 07:51:26 PM
Blimey foody, it sounds like your loom suffered in the same sort of area as mine, but probably a different wire was faulty. Gutted to hear of all your problems, and easy with hindsight, but I do think that after such a failure the garage should've checked for wiring faults sooner. I certainly would have checked as much of it as I could before fitting new units. Can't you ask them to come to the party and at least reduce the labour bill?
In fairness to them they did knock a big chunk off the labour, and some of the parts at cost price to them.
They used to be Kawasaki dealers, but aren't anymore but were in touch with Kawasaki on several occasions over this. (who didn't come up with the crimped wires solution until the other avenues had been tried.
It was almost a case of it being, "the only thing left to check would be the wiring loom and that could be quite labour intensive."... Did I want to go to the expense of that after they had found other connections which had corroded and thought that was the cause.
I'm a regular customer there with my training school bikes so they did give me a good deal on this.
I will be there tomorrow and will ask them if they can pinpoint where the problem was in the wiring.
Wow.... I had speghetti for tea..... Thanks but no thanks.... That looks to be under the seat/tank on the left hand side of the bike....
Interesting location..
Hopefully, mine will go on... But actually, yours is a 2009 isn't it.... Hopefully they changed the loom in 2010.. :-)
53k on mine, but my fob doesn't work that well any more..... Kills batteries within 7 days.
:-)
Thanks for taking the time.
Neil
Hi Neil, right on location, but mine is also a 2010 and has 24k on it. The loom fault was just past the end of the tank, just as it bends under the seat on the left as you state. There's only a few wires there, nothing to worry about! Haha