Falco eletrical problem - engine cutting out

[Loui]

Evening all

Frustratingly, I have an electrical gremlin somewhere on my Falco!

On my way to Pembrey last Friday for a track day, trusty 01 was Falco running well then cut out on the M4. Here's what happened:

- Bike slows and engine stutters as if running out of fuel
- Ignition & fuel lights come on even though tank 3/4 full
- Very mild response to twisting throttle, though engine dies in the end and I coast to a stop
- Battery is flat and would not turn the engine over fast enough to start (new Odessey battery 3 months ago plus I use a trickle charger)
- Unable to bump start even downhill
- All fuses seem OK
- Kill switch not pushed in
- Checked solenoid and seems OK
- Fuel pump seems to be working OK
- 11.2 volts reading from battery whilst engine off (no reading whilst engine running as couldn't get it started again!)
- Battery will now not accept a charge and seems fried

First step is to use original battery (following lengthy charging) and get her started to test voltage, then test regulator / rectifier / alternator, believe I've read of them going on Falcos. Any experience or ideas gents as I am a bit stuck with this?

Cheers all
Loui

[woodbutcher]

sounds like voltage rectifier same thing happened to me when i had a cbr 600 also fried the battery

[Loui]

Cheers Woodbutcher

Update so far:

- Battery re-charged in the end (took about 10-12 hours charging) and now putting out 12.9 V so seems undamaged
- Hooked it up and engine would not even turn over, as though the starter motor would not engage
- Tried another fully charged battery and still the same result

Any further ideas all?

Cheers
Loui

[fastasfcuk]

go for the kill switch i had the same problem last year.i found that if i pulled the button out and held it out it started untill i let go.

[Falcopops]

Is the starter motor spinning?

If so it could be the dreaded sprag! sorry to spread doom and gloom.

Electrical issue does sound like the reg/rec unit

[Loui]

Cheers Falcopops, engine not even turning over. I've since dropped the Falco into my local garage and they have traced the problem to a faulty starter motor and support electrical part of this. Looks like need for replacement, about £400 worth - ouch.

Cheers all for your advice
Loui

[D-Rider]

Cheers Falcopops, engine not even turning over. I've since dropped the Falco into my local garage and they have traced the problem to a faulty starter motor and support electrical part of this. Looks like need for replacement, about £400 worth - ouch.

Cheers all for your advice
Loui

Think we must be able to do better than £400.
I'm sure you must be able to find an auto electricals outfit that can service your starter motor for you. It may just require brushes to be replaced or maybe a rewind but I sure that an economical repair should be possible. If not, a second hand part might be an option.
Do you know what this mysterious "support electrical part" happens to be?
My guess is it's the relay - if so, easy enough to replace. If not that, find out what it is and we'll try to advise.

We'll do our best to save you as much as possible of that £400 - the more you have left, the more beer you can buy us.

[Loui]

That's it - a relay - I forgot the name of the part!

[Kwackerz]

The relay and the starter motor have gone? or just the starter relay?

http://cgi.ebay.co.uk/RSV-mille-R-Tuono ... dZViewItem Ebay, 2nd hand starter

http://www.af1racing.com/store/scripts/ ... oduct=2538 Starter relay / solenoid (Yamaha?)

*does sums on fingers* Under 100 quid.

I'd replace the relay before writing off the starter.

[D-Rider]

Yep - what he says!

The Yamaha relay part number is: 4KD-81-940-00

This one on ebay is also an option:

STARTER RELAY

{This is a 100A relay - the earlier Falcos had a 50A relay which sometimes failed to cope}

[D-Rider]

I'd replace the relay before writing off the starter.

Should be able to check this out without waiting for a relay to arrive.
Short out the switched terminals of the relay (the ones that send the electricity to the motor) with an old screwdriver or something (beware of the sparks - you may feel more secure holding it with gloves on - obviously take care doing this).

If it spins the starter motor, the relay is your problem.



BTW, If the motor doesn't spin, this doesn't guarantee the relay is OK.

[Loui]

Thank you chaps, talk about knowledge!

Sounds like my guy at the garage has done some of the tests that you know about and found the similar results to your expectations:

- Starter motor has engaged but not disengaged, and decided to fry itself asd a result
- Relay also needs replacing as this has gone

So, being the type of guy to spend more on the Falco than on anything else I have decided to bite the bullet and gone for a new starter motor & relay. Starter motor £300, relay £40 both new. I trust the garage as they're friends of mine (DMA Racing, Brinkworth, Wilts) and they're always good when it comes to billing as I buy helmets, boots etc... from them also. Plus I'm the first to say my technical expertise is legendarily poor.

Should get the Falco back in 10 days or so, I'll let you know the outcome. Thanks for your help info, very much appreciated. Hopefully I'll be able to return the favour one day.

Cheers
Loui

[D-Rider]

Just make sure they find out why the starter jammed and fried itself ..... if the problem is that something like the sprag has jammed you could end up frying £300 worth of shiny new starter motor.
Hopefully that's not the case but you don't want to risk the new parts unnecessarily.

[Falcopops]

Should get the Falco back in 10 days or so

Not if the legendary Aprilia parts ogre has anything to do with it!

Hope I'm wrong and you're back on the road quickly. Do pay heed to the potential sprag issue tho'.

[Aladinsaneuk]

sprag clutch off the ducati 916 or higher is a better replacement btw

(Think it is the 916 - but definitly the ducati 9 series)

may want to think about doing the sprag clutch at the same time.... if the parts are open, just do it??