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Old 05-25-2015, 11:09 AM   #1
Roeligan OP
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p0638 - blink code 72 - 2nd throtthle malfuntion

Again... yes again...

History:
2 years ago, middle of nowhere (between Rabat & Cassablanca Morocco) this error pops up & the 100 something horses turn into 7 donkeys. No more power, hard to get at and impossible to get over 120kmh.
Removed the butterfly valves to make it home. Big 'hole' under full acceleration & a lot (too much) noise for my pleasure.
Few days later at home, cleaned everything and tested for a few local rides. No problem anymore .
Last year, leaving for a 10 day ride (about 8000km) in the knowledge everything functions like it should.
Well, it did for the first 8. The last 2 days ride home (2700km more or less), it popped up again. This time I limped home (not having the proper tools to get 1 stuck mini bolt of the butterfly valve loose :() at 120kmh max .
Purchased a second hand injection thing (fastest way to get riding again), problem seems to be solved.
Did a few short & longer rides at home. No problem.
Last Thursday, leaving for a 3 day, 800km allroad (and 600 in total back & forth), again in the knowledge everything functions like it should. Until Saturday
Error code 72 pops up again. Not needing all the horses in the engine, I do not pay that much attention to it. However, it looks like in most cases, when shutting down (turning the key, the killswitch doesn't seem to do same the trick? ) and restarting, it seems to be ok untill I shut it down again. So there might be some restart/reset somewhere.
Limped home (actually only the first 40km of highway, until I could reset the damn thing in a parkingspace) yesterday.

Today, I hooked it up to my laptop & tuneece and did the 2nd throttle body test thingy (after resetting the codes first).
Tuneecu doesn't show the error code immediatly apparently (guess it only reads those codes at first connection with the ecu?), but during the test (ran 5 off them), I always got the 72 blink code on the dash & when resetting the connection with the laptop, the error code shows up in tunecu.

So, now I'm really puzzled.
Took a video of it (https://www.youtube.com/watch?v=6-wS...ature=youtu.be) and it looks like it has difficulties to get the valves closed completely (or is this my interpretation)?
Anybody out there who can actually see if there is happening something odd?

I'm starting to think it must be something electronic, but battery is good (new one), all voltages are within spec (or I must be missing something). Is it possible that there is a faulty connection between the ecu & the injection (complete injection has been replaced, so all wires from the square plug towards the injection are changed too) causing this?

I really, really want a reliable bike again!

Any help is much, very much appreciated!

Thanks!

R
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Roeligan screwed with this post 05-26-2015 at 01:23 AM
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Old 05-25-2015, 06:49 PM   #2
Maoule
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It sounds like something is impeding the full travel of the step motor or you tried adjust the 2nd throttle position and pulled the sensor out of it's base position.
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Old 05-25-2015, 10:03 PM   #3
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Quote:
Originally Posted by Maoule View Post
It sounds like something is impeding the full travel of the step motor or you tried adjust the 2nd throttle position and pulled the sensor out of it's base position.
Don't think so, standard airbox and filter (happens both with the default filter andere the uni filter).
But if so, it should occur Every single time, no?
Schutting down completely solves it from time to time, until a next restart.
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Old 05-25-2015, 11:02 PM   #4
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Can you associate it with very hot conditions?

Was the motor really hot. I am thinking for very strange behavior, the R/R could be overshooting to 18V or so, driving the electronics crazy...
If it happens when the motor is too hot, you could try measuring the voltage then.
Cheers.
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Old 05-25-2015, 11:12 PM   #5
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hmmm... you might have a clue there...
Have to check! (it does occur more when hot when I think about it).
However, I think tuneecu was showing 14.6V yesterday. Too high already?
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Old 05-26-2015, 10:43 AM   #6
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Regulator shows, measured over battery, no more thans 14.something.
Diodes are fine according to my multimeter.
Ran a test. Cold -> no issue at first.
Warm same error.
Anything else I can check?

Edit: revving the engine shows speedo activity. Regulator afterall?
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Old 05-26-2015, 11:11 AM   #7
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When connected to tuneecu, is your 2nd throttle position sensor voltage correct? Is the connector seated all the way?
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Old 05-26-2015, 11:31 AM   #8
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Quote:
Originally Posted by Maoule View Post
When connected to tuneecu, is your 2nd throttle position sensor voltage correct? Is the connector seated all the way?
0.65 cold

All connections look good...

When revving and warm I see values up to 0.84.
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Old 05-26-2015, 03:16 PM   #9
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If you could measure your voltage when the engine is hot?

R/R s fail when hot while they can still operate normally in milder temps.
Cheers
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Old 05-26-2015, 04:25 PM   #10
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p0638 - blink code 72 - 2nd throtthle malfuntion

I'm mistaken about the tuneecu checking the 2nd throttle position voltage. You need to check it with a VOM.
I had a similar problem with mine- the 2nd throttle step motor couldn't find home position because I had removed the position sensor housing and didn't put it back correctly, resulting in a voltage that was too low or too high. The stepper motor kept cycling the same way yours is in the video. So I wonder if something is going on with your 2nd throttle position sensor when it gets hot. The voltage should be 1.0v

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Old 05-26-2015, 11:17 PM   #11
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Quote:
Originally Posted by Maoule View Post
I'm mistaken about the tuneecu checking the 2nd throttle position voltage. You need to check it with a VOM.
I had a similar problem with mine- the 2nd throttle step motor couldn't find home position because I had removed the position sensor housing and didn't put it back correctly, resulting in a voltage that was too low or too high. The stepper motor kept cycling the same way yours is in the video. So I wonder if something is going on with your 2nd throttle position sensor when it gets hot. The voltage should be 1.0v
Not convinced its the tps. Same issue with another one. I already replaced the complete injection unit.

However, this morning, measuring regulator voltage again, over the battery, i did notice drops when revving. Shouldnt occur imho.
Read an other thread (gefr, where you also mentioned this) that its actually the regulater failing. Time to order a new one I think...
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Old Yesterday, 01:19 PM   #12
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Quote:
Originally Posted by gefr View Post
R/R s fail when hot while they can still operate normally in milder temps.
Cheers
So, installed a MOFSET FH020AA this evening.
Hot, cold, low, high rpm -> rock steady voltage
Tested the 2nd throttles using TuneEcu (hot & cold) -> no more issue so far

Could it really be that my issues are gone? End of next week a promising +25 C, should be more than enough to try to see if it's really solved.
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