ECU Replacement

[Foody]

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.

[Debs]

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

[virginiajim]

Have never heard of this issue before..

[Rotorbike]

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 

I'd say you'd get another 69,000 miles from a second hand unit.....

[Kwikasfuki]

Whereabouts is the regulator/rectifier on the bike?

[Richard]

Whereabouts is the regulator/rectifier on the bike?

Underneath, above / bit forward of back wheel.

[Foody]

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.

[Richard]

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

[Foody]

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.

[Debs]

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.

[Foody]

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!

[Foody]

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!

[virginiajim]

Where were the wires crimped?

[Richard]

  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

[shaggs147]

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?