Topendcol

Hey Mech, Long time. Took bike to mechanics to confirm PCM, only charged us $150. Ordered PCM, $900 AUD wasn't an easy purchase but plugged it in and she worked no worries. The gear shift isn't playing up either so it might be related to the PCM. Side note, I found the cheapest PCM in NZ, but they wouldn't ship to AUS. The US PCM had one different letter in the part # so i didn't want to take the risk, would of saved $250 but didn't want to risk it. Thanks for your help, and without this platform and the service manual it would of cost a sh** load more.

Not much cheaper over the ditch in Oz. Especially with the dollar rate to US. Not to sure which way to go about it (PCM BYPASS) but done the ground control wire bypass for the fuel pump and it seemed to work. Not looking forward to spending $600 for PCM and it wont work fix it, cant see any other options ATM. Ran both PCM tests and they both indicated it was faulty. Hopefully it'll get her running again. Then need to work on the power steering and auto shift. The power-steering has never really worked, and in the owners manual it mentions that prolonged outage may cause damage to the system. I recently done the steering reset to clear the DLC fault but didn't fix the issue. The PS light is still illuminated on the combo meter. No other DLC faults come up on the meter. So was gunna pull out the shift control motor and hard wire it for testing. Also seen online people pulling out the shift motor housing/gearing, cleaning it and re-greasing. Probably purchase shift angle sensor and replace as well. Had issues for a few years now with the auto shift, once the quad runs for an hour or so the '-' indicator comes on and wont let ya shift. Have to let it cool down and go again. Not sure if its all related but even if the power steering and shift motor are faulty, the bike should be able to start regardless. So makes me think the PCM is the most likely issue (for now). Thanks for getting back to me, I know it all takes time and I appreciate your efforts. PS.... My old man is Kiwi, and his two mates are A grade Mechanics as well. Must be something over there to create great Mechs. Cheers

Checked the ground signal for the fuel pump, no continuity to ground. Bypassed the ground signal and earthed to the relay, the pump runs. Checked the main earth continuity to the PCM, all good. Went through the service manual again, done the serial communication line tests and the PCM power/ground line tests. All roads lead to replacing the PCM . Had suspicions but its good to be 100% sure.

Thanks Mech Ive been testing with a new LED test pen, I think i should try dig up my old globe style test pen, definitely makes more sense. Was under the assumption it's working because with the relay removed the power lines for the coil/inj/pump junction connector are dead but active when installed. But cant get the switch wire for the pump to work even with the control wire switched. But as you mentioned, could be getting a faulty reading on the control wire. As for the earth, I'm not sure there is any earths on this relay, doesn't appear to be on the wiring diagram. May be some sort of inductive switching but I'm not sure. Will try the bypass method, that was my next go to. Hoping it is something simple as a broken wire, I cant start the bike or even change gears on the Auto shift, just get the flashing '-' were the 'N' is meant to be. So up sh** creek ATM. Ive also replaced the combination meter but that didn't work. The old display was unreadable anyways so needed replacing. Just seems like Im missing something. I'll keep pursuing. Do you know if the PCM (main computer) switches the earth or does it send a positive output. Does appear on second looks at the diagram that it completes the earth circuit. I may have been looking at this the wrong angle. If thats the case the PCM may be corrupt. But will check all bases first, could imagine those wont be cheap.

First issue was fuel pump wont start once ignition has been turned on. Replaced the pump as I had one on hand, than noticed no power so replaced the fuel pump relay as that was were i traced the power to. Still nothing so further inspection looks like signal is coming from the PCM (FLR B20) but not switching the the brown wire to the fuel pump. Ive checked the operation of the bank angle sensor and it appears operational. Fuses and wiring all appear OK. The engine stop relay also tests OK. Ive been through the repair manual and diagrams but to no avail. Fully stumped, any tips would be helpful. Thanks Col