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  1. #1
    Very Active Member Bering_C_Sparky's Avatar
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    Default Broke down today

    Well I broke down earlier today and had to get the wife to connect the trailer to the truck and come get me.

    Got it back home and charged the battery while I ate dinner then went back to the garage to see whats going on.

    I have compression in both cylinders (thank god) but no spark.

    Gonna dive into it and see WTF is up.

    First pic is my bike int he trailer, second picture is the wife showing me what she thinks of having to come and get me from the side of the road.
    The whole way home I kept telling her that I blew it up and will need to buy a new one.....she was not happy to say the least.
    (Its not blown up....I just like messing with her)

    Will update after I get the bike going again.

    BCS

    (Forum keeps turning my photos sideways)
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    Last edited by Bering_C_Sparky; 10-30-2018 at 10:26 AM.

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    Very Active Member Sargeant002's Avatar
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    Ah! No good man!

    Keep us updated!

    ~Brian II

    Sent from my SM-G965U using Tapatalk

  4. #3
    Very Active Member FlyingCircus's Avatar
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    LOL

    Sleeping on the couch tonight.


    At least it will be electrical so you'll be able to figure that out fast

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    Very Active Member Latinrascal's Avatar
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    Quote Originally Posted by FlyingCircus View Post
    At least it will be electrical so you'll be able to figure that out fast
    I Hope BCS can figure it out quickly however in my experience its the Electrical problems/Gremlins that are the hardest problems to solve! Not impossible by any means just not as straightforward as the Mechanical parts. Of course if you have all of the proper testing equipment and electronics Knowledge it makes things easier that for sure!

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    Good luck with the spark, Sparky. Won't that wiz bang computer give you the answer? Check your grounds.

  8. #6
    Very Active Member Bering_C_Sparky's Avatar
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    Quote Originally Posted by Metalman View Post
    Good luck with the spark, Sparky. Won't that wiz bang computer give you the answer? Check your grounds.
    LOL....See Below.

    I actually took the tablet off the bike first because it was in the way to pull the tank....

    Found the Crank Position Sensor was bad the old fashion way....with a ohm meter.

    Then a friend messaged me and when i told him it was the Crank Position Sensor.....he said what FI code did I pull?

    Hmmm.....Odd thing was the bike was not throwing any FI indication at all (also see below)......so I never bothered to try and pull a code.

    Thats when I connected the tablet back to the bike and pulled the Error code below for confirmation.

    BCS
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    Last edited by Bering_C_Sparky; 10-30-2018 at 02:27 AM.

  9. #7
    Very Active Member Bering_C_Sparky's Avatar
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    As long as its really just the CKP bad and nothing more sinister then I am Aces.

    Will get one ordered in the morning.

    BCS
    Last edited by Bering_C_Sparky; 10-30-2018 at 10:41 AM.

  10. #8
    Very Active Member Bering_C_Sparky's Avatar
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    And the 3rd and final confirmation......a visual inspection.

    The Crank Position Sensor is toast.

    BCS
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  11. #9
    Very Active Member Bering_C_Sparky's Avatar
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    Figure I will go ahead and change the front motor mounts since the bike is down anyway.

    Went ahead and stripped the bike down and pulled the exhaust, will drain and remove the radiator in the morning and go ahead and install those silicone coolant hoses i picked up a while back.

    Big Red is gonna get a unscheduled oil and coolant change.

    BCS
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  12. #10
    Very Active Member Latinrascal's Avatar
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    Quote Originally Posted by Bering_C_Sparky View Post
    And the 3rd and final confirmation......a visual inspection.

    The Crank Position Sensor is toast.

    BCS
    Well there is definitely no doubt that CPS is bad, Wow! What do you think caused it to burn up like that? Do you think it was just the sensor or or do you think that something up the line caused the burnout? From the pictures it doesn't look like it simply just Failed, it looks like it's been in a fire or had a high voltage spike or whatever its called! I ask because this should have thrown an fi code and the fact that it didn't may indicate there is a problem upstream within that circuit somewhere!
    Last edited by Latinrascal; 10-30-2018 at 07:41 AM.

  13. #11
    Very Active Member Richard's Avatar
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    Glad to hear that is only the TPS. I think because you are experimenting with different programs I would order at least two.

  14. #12
    Very Active Member Bering_C_Sparky's Avatar
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    LOL.....it had nothing to do with my tuning the bike.

    The retaining clip that holds the sensor to its mount came off and the sensor got ground down when it made contact with the rotating parts. (It did not burn up)

    Odd though, Suzuki does not list a separate part on the bike as Crank Position Sensor.

    The part in the picture is listed as a pulser pick up and is sold as part of the stater assembly.......$600 retail (my suzuki dealer said they would sell it to me for $480)

    Still looking for plan B first before I lay out that kind of cheese.

    BCS
    Last edited by Bering_C_Sparky; 10-30-2018 at 10:24 AM.

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    Very Active Member Hogan109r's Avatar
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    I was wondering if you would take a brighter picture of this part
    for me. I just cant see it very good.Thanks

  16. #14
    Very Active Member Latinrascal's Avatar
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    Quote Originally Posted by Bering_C_Sparky View Post
    LOL.....it had nothing to do with my tuning the bike.

    The retaining clip that holds the sensor to its mount came off and the sensor got ground down when it made contact with the rotating parts. (It did not burn up)

    Odd though, Suzuki does not list a separate part on the bike as Crank Position Sensor.

    The part in the picture is listed as a pulser pick up and is sold as part of the stater assembly.......$600 retail (my suzuki dealer said they would sell it to me for $480)

    Still looking for plan B first before I lay out that kind of cheese.

    BCS
    Wow thats ridiculous for something that is little more then a magnetic pick up sensor! Reminds me of the "Tube Nut" situation where it only comes as a complete clutch basket assembly which is strictly A Money Grab scam IMHO.....sorry I assumed it was burnt up but i was just going by how dark and toasted it looks in the picture you posted.

    As a Plan B.......Id definitely do a Search for used but i would also check the specs for other suzuki bikes like the busa and gixxers to see what part they run and if they use the same part or not. Ive found that parts shared between different vehicle platforms dont Always cost the same for the very same exact part. Sometimes its the same exact part that has a different connector and you will need to either change the plug or cut it off and hardwire it in to make it work but it could save you alot of money being willing to do so.

    Plan C- I did a qick search and found this after market stator that comes with the Pulse pickup sensor for $209 Canadian and i think its $159 for US sales.....maybe you can find just the Pulse pickup sensor from an aftermarket supplier! https://www.rmstator.com/en_ca/products/stator-rm01596
    Last edited by Latinrascal; 10-30-2018 at 01:11 PM.

  17. #15
    Very Active Member cbxer55's Avatar
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    Where is this sensor located on the bike? Might be something that needs to be checked now-and-then. But truthfully, this is the first I've heard of it on this site.
    SILVER 2006 M109R.
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    Very Active Member NoSetFine's Avatar
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    Wow crazy! Awesome that you could so quickly diagnose and confirm it like that (probably punishment for being able to ride all year...ha) - I have no such Kung Fu for that kind of failure. Nice.

    Your wife is hilarious. That pic made me laugh. Mine would not have even picked me up. Haha.


  19. #17
    Very Active Member Bering_C_Sparky's Avatar
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    Its nice to have a friend with a parts bike.

    I already have a pick up removed from another bike that caught fire.
    The wiring on the outside of the engine case was all burned up but the wiring and the sensor inside the engine case are all fine.
    So I just took the pick up (bracket and all) off the stator and cut the wiring on the inside of the harness oil seal.

    Will get it soldered into my bike after I eat lunch.
    It will be tomorrow before I can put it back together since I had to order a new gasket.

    So I will go ahead and change the motor mounts and coolant lines today while the bike is apart.

    Hogan109r
    I was wondering if you would take a brighter picture of this part
    for me. I just can’t see it very good.Thanks
    Sure, I will post some better pictures tonight.


    cbxer55
    Where is this sensor located on the bike? Might be something that needs to be checked now-and-then. But truthfully, this is the first I've heard of it on this site.
    It is mounted just a 1/2 inch from the stator, under the left crank case cover.
    I am sure this does not happen often.....I am just lucky like that.

    BCS
    Last edited by Bering_C_Sparky; 10-30-2018 at 02:16 PM.

  20. #18
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    Quote Originally Posted by Bering_C_Sparky View Post
    Its nice to have a friend with a parts bike.

    I already have a pick up removed from another bike that caught fire.
    The wiring on the outside of the engine case was all burned up but the wiring and the sensor inside the engine case are all fine.
    So I just took the pick up (bracket and all) off the stator and cut the wiring on the inside of the harness oil seal.

    Will get it soldered into my bike after I eat lunch.
    It will be tomorrow before I can put it back together since I had to order a new gasket.

    So I will go ahead and change the motor mounts and coolant lines today while the bike is apart.



    Sure, I will post some better pictures tonight.




    It is mounted just a 1/2 inch from the stator, under the left crank case cover.
    I am sure this does not happen often.....I am just lucky like that.

    BCS
    Just read this. Glad you got one. I was going to check my parts bike in the shop to see if it is still there. I was going to send it down to you but since you are all sorted out, if it is there I will keep it where it is :-)
    Formerly known as BigpapaM109

  21. #19
    Very Active Member Bering_C_Sparky's Avatar
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    Quote Originally Posted by bigpapaXCT View Post
    Just read this. Glad you got one. I was going to check my parts bike in the shop to see if it is still there. I was going to send it down to you but since you are all sorted out, if it is there I will keep it where it is :-)
    Thanks Harris, I appreciate that.

    Will know tomorrow how it all pans out but hopefully what I have here will work fine.

    BCS

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    Quote Originally Posted by Bering_C_Sparky View Post
    Thanks Harris, I appreciate that.

    Will know tomorrow how it all pans out but hopefully what I have here will work fine.

    BCS
    You're welcome Charles. I am going over the shop in an hour so i will see if I at least have it. I sold the chrome cover and had to remove the guts so no clue where anything is.
    Formerly known as BigpapaM109

  23. #21
    Very Active Member cbxer55's Avatar
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    Quote Originally Posted by Bering_C_Sparky View Post

    It is mounted just a 1/2 inch from the stator, under the left crank case cover.
    I am sure this does not happen often.....I am just lucky like that.

    BCS
    I knew it had to be near the crankshaft, obviously. Didn't know what side or which cover it was under. Too bad it couldn't have been located under the otherwise useless derby cover.
    SILVER 2006 M109R.
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  24. #22
    Very Active Member FlyingCircus's Avatar
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    That would have been a pain to track down. Glad you got it figured out so soon and at least you'll get motor mount bushings changed out too. And lucky your buddy had part, that's not cheap at all

  25. #23
    Very Active Member Bering_C_Sparky's Avatar
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    Couple of pictures before and after I spliced the new pick up in.

    BCS
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  26. #24
    Very Active Member Bering_C_Sparky's Avatar
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    Couple more pictures of the old pick up that got damaged.

    BCS
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  27. #25
    Very Active Member FlyingCircus's Avatar
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    so the 2 hex nuts came loose or something else. I'd imagine if the hex nuts came out there would be much more damage

  28. #26
    Very Active Member Latinrascal's Avatar
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    Quote Originally Posted by FlyingCircus View Post
    so the 2 hex nuts came loose or something else. I'd imagine if the hex nuts came out there would be much more damage
    Its still kinda hard to see because of the really blurry pictures but it looks like the screws maybe just loosened up enough for the sensor to have enough free movement that allowed it to "Tip" towards the rotor face where the case was Rubbed through until the inside got exposed enough to short out... At least that's my theory based on BCS explanation of it getting pulled into the moving parts!

  29. #27
    Very Active Member Bering_C_Sparky's Avatar
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    Quote Originally Posted by FlyingCircus View Post
    so the 2 hex nuts came loose or something else. I'd imagine if the hex nuts came out there would be much more damage
    Nope the screws that hold the bracket stayed in place and did not come loose.

    There is a metal clip that secures the pick up to the metal bracket......this clip came off and then the pick up was just floating.

    I got the motor mounts and the coolant hoses changed out last night and got my crank case gasket late this afternoon but was not able to work on the bike today.

    We had the Post 911 fallen hero's memorial set up in our town this week. Today was its last day here, so the wife and I went to help break it down and pack it up. Its now on its way to Lexington Kentucky.

    The American Legion Riders Group I belong to traveled to Tallahassee last Thursday and escorted the memorial to our town, I was not able to make that ride so I made sure I was there to help out packing it up.

    Very humbling walking though the rows of photos and seeing the sacrifice our young men and women have made......Freedom is not Free.......something that is all too easily overlooked and forgotten these days.

    There is a Gold Star family that is transporting this memorial around the country, we took them out for dinner and drinks after we got the memorial packed away......Really good people.

    BCS
    Last edited by Bering_C_Sparky; 10-31-2018 at 09:23 PM.

  30. #28
    Very Active Member Bering_C_Sparky's Avatar
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    Some of the photos are blurry because I used my phone and the camera sucks.

    Here are a few photos of the silicone coolant hose kit I ordered a while back on Ebay.

    I was a bit surprised to find out today that the silicone hose kit contained only the 3 top hoses and not the bottom hose.

    I checked to see if my local dealer had a bottom hose in stock.....but no such luck, there was only one available in the entire country and it was located in Atlanta Georgia.

    Guess I will change the bottom hose at another time, tomorrow the bike goes back together, no if, ands or buts about it.

    BCS
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  31. #29
    Very Active Member FlyingCircus's Avatar
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    Quote Originally Posted by Bering_C_Sparky View Post
    Nope the screws that hold the bracket stayed in place and did not come loose.

    There is a metal clip that secures the pick up to the metal bracket......this clip came off and then the pick up was just floating.

    I got the motor mounts and the coolant hoses changed out last night and got my crank case gasket late this afternoon but was not able to work on the bike today.

    We had the Post 911 fallen hero's memorial set up in our town this week. Today was its last day here, so the wife and I went to help break it down and pack it up. Its now on its way to Lexington Kentucky.

    The American Legion Riders Group I belong to traveled to Tallahassee last Thursday and escorted the memorial to our town, I was not able to make that ride so I made sure I was there to help out packing it up.

    Very humbling walking though the rows of photos and seeing the sacrifice our young men and women have made......Freedom is not Free.......something that is all too easily overlooked and forgotten these days.

    There is a Gold Star family that is transporting this memorial around the country, we took them out for dinner and drinks after we got the memorial packed away......Really good people.

    BCS
    That would be quite humbling. But good they are traveling and keeping in peoples minds, lest we forget


    So the hoses aren't really worth the money then as they're not complete

  32. #30
    Very Active Member NoSetFine's Avatar
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    Cool hoses - I had my finger on the trigger for blue ones when they were mentioned and you bought yours but had second thoughts of what that would look like on grey/black BOSS - I think the red should look prettu sweet on yours though. Looking forward to pics mounted!


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