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Discussion Starter #1
Hey Guy,
Been a while since I have been here. I need some help please. My bike died on me going home last Wednesday. I could get it to start but it would sputter, backfire and stall after running the idle over 2k.

I checked the codes and got an o2 sensor code, so I started with the least expensive part of the system fuel filter needed replacing and checked the pump.I have replaced the Ignition coil (ohm'd out low), both o2 sensors. I have checked all of the connectors that come from the wiring channel under the tank to the injectors, I have checked for intake leaks. Hell I even broke open the timing case to see if I lost a chain tensioner. I have disconnected the power commander and plugged directly into the ECU and the result is the same. What am I missing?

Any ideas?
 

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So tough to help diagnose from so far away. I'd still say fuel. Sounds like a lean condition to me. You could also have lost your TBW connection. Do you have aftermarket bars? Did you replace that green plug with an SE TBW sensor? Just spitballing here.
 

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Discussion Starter #3
I do have aftermarket bars, I added 14" Z-bar apes about a year ago. I unpinned the stock plug and ran the wiring internal and re-pinned it. I was thinking last night that maybe one of the throttle wires had possibly chafed through and was grounding inside the bars. Something else for me to check I suppose. Honestly all that I have left to consider in the systems are the Crank position sensor and possibly a hole worn through the feed tube in the tank coming from the pump. And of course the ECM itself.

Thanks for the response it kind of confirms my thinking.
 

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Actually, the more I think about it, after changing the o2 sensors last night and firing it up, it started immediately which it hadn't been doing, went right to 1000rpm for about 30 seconds and then ran up to about 2K then dropped down to around 600 sputtered and backfired. Did that for about two minutes. After I shut her down I checked for codes and had none. That really makes me thing fuel more that Crank position sensor.
 

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Could be a dirty IAC, you might could clean it or replace it. Bad TPS? Just some suggestions.
 

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OK step back and start over. What was the code(s)? Some 02 codes relate to the sensor itself and some relate to what it is seeing. Each code has a specific diagnostic ladder that greatly reduces the replacement of parts based on hope. "I hope this fixes it" can be a very expensive repair strategy.

On a 09 with a idle speed issue, the first thing to do would be to clean the terminals in the throttle body connector.

Record the codes and then clear them. Clean the connector pins. You almost have to release them from the connector to get them clean. Then reinstall and see how it runs and if it codes again. If it runs poorly or codes, diagnose it accordingly. If it fixes it, go on down to the MoCo with some money and a band-aid and buy a set of new terminals. If you don't have the tool to crimp them on with, it's cheaper to pay them to do it as opposed to buying the tool.

Next thing to buy would be the Electrical diagnostic manual, 99497-09. Best $50 you'll ever spend on that scooter.
 

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Discussion Starter #8
I already checked and cleaned the TPS, had not thought about the IAC. Thanks
 

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If you checked the TGS in the handlebar and it didn't solve your problem then go down to the throttle body and check the TCA plug, pull it off and check for cracks in the wiring and put dielectric grease on the plugs connections before putting the plug back on. It is also possible that the TCA motor in the throttle body has gone bad and the only way to fix that is with a new throttle body. It's highly unlikely that the crank position sensor is bad and if the fuel lines in the fuel tank are sucking air you can test that by filling the fuel tank to the top and then run the bike if the bike runs fine for awhile then starts to run bad as the fuel level drops then it is possible that there is a crack in the fuel fuel line. There is also a history of the fuel filter canister warping and sucking air so check that. When you get DTC's usually the first code is the problem and the other codes are secondary codes so instead of working your way from the last code to the first just start with the first code. Also check the wiring at the ECM plug, there have been instances of aftermarket seats rubbing the ECM plug and wires and causing running issues. Hope you find the problem, of course I'm just giving you a few possible causes the problem may be elsewhere. Good luck.
 

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Discussion Starter #15
Found it! After checking the fuel pressure I realized that although I was getting fuel the pressure was to low. Thought maybe I had an internal fuel line that had worn through. Took the Fuel pump assembly back out and one of the plastic tabs was broken off of the fuel filter housing. This internal leak caused the pressure to drop. It was actually squirting fuel inside the tank. So something to consider checking if your bike has an acute occurrence of sputtering and idle searching. Back on the road she is, I no longer feel dead inside...HAHA!
 
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