Author Topic: 2011 S1000RR wont start, injector valve fault??  (Read 13725 times)

fmo

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2011 S1000RR wont start, injector valve fault??
« on: January 01, 2016, 02:56:08 AM »
On nightshift one hour into the new year, and have some time now to seek help from this forum ;)

The story so far:

About 2 months ago I bought a 2011 S1000RR race bike. Quite modified chassis and electronics but standard engine, hardly used (1400 km) - previously spare bike for a race team. Former owner just used it for about 5 trackdays, had a crash and lost the spirit. Bike had been standing for about 2 years when I purchased it. In the following month I did some small cosmetic repairs from the former owners crash, started the bike several times in that period and the bike always started right up. A couple of weeks ago I decided to change engine oil and filter before winter storage. Took bike out of garage and drove up and down my driveway some times to heat up the old oil before draining it, suddenly the bike stops and wont start again. I open the fuel cap and realize the tank is empty (race bike-fuel level disconnected).
So I continue with the oil change procedure since the bike was already warmed up, when that is done I get some fresh fuel on the tank and expect the bike to start right up again. But it wont, not even a small hint of trying to start. I try several times, but it is not catching at all. I notice that there is no smell of fuel in the garage during these attempts, so I come to the conclusion that the fuel pump probably is ruined because of old gas and bottom slug after 2 years of not in use.
So I order a new pump and at the same time a GS911 wifi that I already had decided to buy.

So yesterday both the fuel pump and the GS911 arrives. Earlier today I had some spare time so decided to test the GS911 and found this:

AutoScan Report
GS-911 version: 1511.2 Datapack version: 3.3
Serial Number: GS1 002 661
Firmware version: 0.239-0.132 Datapack version: 0.122
Registered to: Frode Moe
Date: 31.12.2015 Time: 13.06.01
Motorcycle Information
VIN: WB1050706BZ070640
Mileage: 1104.0 km
Cluster date: 31 desember 2015
Next service date: 30 desember 2016
Next service distance: 11104 km
Factory I-Level: K024-10-08-500
Actual I-Level: K024-11-08-510
BMS-KP2
BMS type: BMS-KP2
Part No.: 8521664
Hardware Index: 36
Coding Index: 03
Manufacture Date (YY/MM/DD): 2010-11-12
MCV: 0.6.2
FSV: 0.77.51
OSV: 2.3.1
Manufacturer: Bosch
HWOE No.: 68175813
Program status: 510I
Date release: SA10
Factory I-Level: K024-10-08-500
Actual I-Level: K024-11-08-510
VIN model year: 2011
10 fault codes found:
10153 Injector valve 4
The fault is currently present.
GS-911 AutoScan Report 31.12.2015 13.06.34
Page 1 of 3
10154 Injector valve 5
The fault is currently present.
10155 Injector valve 6
The fault is currently present.
10156 Injector valve 7
The fault is currently present.
10157 Injector valve 8
The fault is currently present.
10444
Fuse activated for component Ignition Supply (starter relay, Immo (EWS) ring antenna, ignition coils,
injectors)
The fault is not present now.
10150 Injector valve 1
The fault is currently present.
10085 Output stage defective of Secondary Air Valve 1
The fault is currently present.
10151 Injector valve 2
The fault is currently present.
10152 Injector valve 3
The fault is currently present.
CAN-Kombi-K46
Cluster type: CAN-Kombi-K46
Part No.: 7721877
Hardware Index: C3
Coding Index: 02
Manufacturer: Siemens VDO Automotive
Manufacture Date (YY/MM/DD): 2007-01-01
MCV: 0.6.3
FSV: 1.4.0
OSV: 4.2.0
HWOE No.: 61777453
Assembly No.: 7721877
Factory I-Level: K024-10-08-500
Actual I-Level: K024-11-08-510
4 fault codes found:
37801 Headlight (Low-/High-beam) Relay open circuit
The fault is not present now.
37794 Park light open circuit
The fault is currently present.
GS-911 AutoScan Report 31.12.2015 13.06.34
Page 2 of 3
37784 Discrepancy in values of total mileage (>100km) between BMS-KP and KOMBI (instrument cluster)
The fault is currently present.
37792 Rear/brake light open circuit
The fault is currently present.


Is it possible that a poor fuel pump can give these codes? Is it even possible that all 8 injectors can fail? Is it a fuse or relay that I may have overlooked?
I can hear the fuel pump prime when I test it with the GS911. I have also tried the injector test on all injectors, but that made no difference.

I hope someone can chime in with some help or hints on this, but I will anyway try the new fuel pump before I start to tear down something else.

Best regards and happy biking in 2016,

Frode

WayneC

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #1 on: January 01, 2016, 05:49:05 AM »
You mentioned that the electronics are modified, exactly what are the modifications ?

The Autoscan is indicating a fault with the injectors rather than the fuel pump and you indicate you can trigger the pump with the GS911

fmo

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #2 on: January 01, 2016, 06:08:02 AM »
Thats right, I could prime the pump via GS911.
But I dont hear it prime when I power on the bike.

Bike has keyless ignition with Alpha Racing EWS antenna, it has Alpha Racing DTC controller with ABS completely removed.
There is also a HM+ quickshifter.
It also has race handlebar switches and li-ion battery.
Logically in my mind the fuel pump would be the prime suspect, but it is strange that it gives no fault code. I also think it is strange that all 8 injectors could be faulty
at once??
« Last Edit: January 01, 2016, 06:10:38 AM by fmo »

WayneC

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #3 on: January 01, 2016, 06:34:11 AM »
Understood re the electronic modes, they should not be a factor in the fault

While I dont know the BMSKP all that well as I mainly look at the BMS-C/BMS-E of the singles, they have moved to firmware logic in the BMS systems to determine whether components should be powered up/triggered when ignition is turned on so in this case since you can trigger the fuel pump with diags but it does not prime when ignition is turned on then it suggests the fault in the injectors is the cause of the BMSKP not activating the fuel pump. I would see if the injectors can be pulsed under diags and look around the wiring for the injectors as a starting point

fmo

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #4 on: January 01, 2016, 06:56:03 AM »
Thanks for advice!

I will take a closer look on this after the weekend and report back.
I did try to test the injectors via GS911 but that made no difference.
Do you know if one is supposed to hear some kind of sound during the injector test?
There was no detectable sound from any of the injectors during my test.

WayneC

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #5 on: January 01, 2016, 07:18:05 AM »
Injectors are best tested out of the bike so you can see/feel the fuel mist. Any old spare with the right connector is rather handy for testing

Since the fault shows on all injectors it suggests loss of power or some other connection common to them all, a fuse perhaps ?  ;D

fmo

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #6 on: January 04, 2016, 01:31:27 PM »
Ok, happy to say that the problem is fixed. It was the quickshifter...
First I sprayed some brake cleaner down the throttle bodies while cranking, and the bike catches. Then I definitely know its a fuel delivery issue. Next I put in a new fuel pump, but while testing the old one on the bench I start to doubt that the pump is the culprit, the old pump seems to work just fine. So with the new pump - no start - and the same fault codes on all the injector valves.
Then I disconnect the loom for the HM+ quickshifter that is inline with the injectors, hooks the BMW harness back directly onto the injectors and BAM, she fires right up and no fault codes ;D. Thanks for all help, now I will take the multimeter and see if I can find the fault on the HM loom.

WayneC

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Re: 2011 S1000RR wont start, injector valve fault??
« Reply #7 on: January 04, 2016, 01:44:53 PM »
Well you know now not to trust my judgement  ;D, I dismissed the quick shifter without checking how it was set up, I assumed it was rpm based off other signals, would not have guessed injector wiring was involved but pleased you have it sorted