02 VFR quit while riding and now will not start

Discussion in '6th Generation 2002-2013' started by drrocka, Nov 25, 2016.

  1. drrocka

    drrocka New Member

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    Was headed out of town, had ridden about 15 miles when the bike (at 80+ mph) just quit like the key had been turned off. I pulled over and checked connections, fuses, etc. and bike will crank but will not start. I have tried pulling the 2 fuses and can hear a loud click with key on, which sounds like a relay being clamped. It appears that the fuel pump is running and the FI light goes off after a couple seconds like it normally does.
    It seems as if what is supposed to be firing the DI coils is not sending the signal. It's been a while since working on anything on the bike; usually just get on and ride. It does a PowerCommander 5 and a SpeedoHealer installed which I did myself almost a year ago. Never had any other issues with the bike since buying it last summer with only 5900 miles; it now has about 11,500 miles on it.
    Any idea where to start with this thing other than making sure that there is no spark to the plugs?

    Thanks
     
  2. Diving Pete

    Diving Pete Member

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    do you smell fuel after cranking>?
     
  3. Diving Pete

    Diving Pete Member

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    & just as a really dumb question - you didnt hit the turn off switch on the right handle bar ?
     
  4. drrocka

    drrocka New Member

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    Pete, Yes when I gave up on it starting and went to push the bike to a safe place until I could get a friend to come pick me up, I could smell gas. You can hear the fuel pump running / priming for a few seconds after first turning on the key and the FI light goes off when it quits. Also, I put a pair of ConvertiBars on the bike so I checked that one of the wires to the controls on both sides are still firmly connected. When you turn the kill switch off on the bars, it won't even crank so that seems to be working. Haven't had a chance to run any electrical checks at all but with the kickstand down it won't crank either so I feel that is not the problem either. I already replaced the weak link in the main fuse wire at the battery with a heavier-gauge setup and have not had any issues since with that.
    A little more info, I bought the bike from a powersports shop in San Antonio. They had picked it up from a young military guy that had let it sit in the garage for too long. The bike had less than 5900 mi and I paid $3500 after they put a brand new set of Michelin Pilot Sports on it. They said that they had spent too much money restoring the bike to top running condition to sell it for less (even though I tried). Said they had to remove and send the fuel injectors off to be serviced too. Not sure what all they did to the bike but it has run very well since I bought it.
    I need to get the tank and bodywork off the bike when the weather gets nice (hopefully in the next day or 2) and do some more investigation. I read on one of the other similar threads that there may be some module or something that controls the distribution of signal to fie the individual coils.
     
  5. Lint

    Lint Member

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    Have you found anything? I'd start at any wiring you've done, then move on to anything the dealership did. Then go to the factory bits that remain.

    Sounds like no spark, but that's a complete guess.
     
  6. RVFR

    RVFR Member

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    like what Lint, said sounds like a ground out, that's what the kill switch does, IDK though. one of those touchy feely things, Ones going to have to take a muti tester and start the check this and that I'm afraid, unless there's a fuse just for the coil packs? It will be interesting to know what you find out.
     
  7. Grumpy old man

    Grumpy old man New Member

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    Check the ground for the Power commander if this is loose it will crank and not fire
     
  8. goinphaster

    goinphaster New Member

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    I second this!!
     
  9. drrocka

    drrocka New Member

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    Sorry guys but work, travel, and weather took me away for a bit. Finally got around to doing more diagnostics and, as I said before, it was particularly baffling because everything looked and sounded normal. Pulled the left side bodywork and pulled plug wire from #1 to check for spark and found that it actually had a strong spark. So, I lifted the tank and pulled the old can of starting fluid, sprayed a bit through the snorkel on the air cleaner housing, and sure enough it tried to run on the starting fluid so I now knew that it wasn't getting fuel. There was plenty in the tank so I started troubleshooting from the service manual. I pulled the rest of the bodywork; left-side and the front fairing with lights to check for FI codes but found none which was really confusing. Since I knew that the bike had been sitting for an extended period prior to me purchasing it, I went ahead and ordered a new fuel filter from the local Honda shop. While troubleshooting I recalled once hearing as if fuel was thrashing in the tank, which I had not heard when the bike was on the side stand but it was now on the service stand. Sure enough when the filter came in and I went to check / install I found what you see in the image attached. The filter had been replaced with a different one which had straight inlet and outlets (not the curved tubing on the inlet side as the factory replacement had) and the hose (between the pump and the filter) and clamps had also been replaced. The clamps were not tight enough so the main fuel line from the pump had come off! You can see in the picture how bad the whole thing looked from sitting for long periods with apparently no fuel in the tank. You can also see that the other smaller line had some small aftermarket filter attached (and was pull-tied to the clamp) but that line was also rotted and broken off. I tried to clean the entire assembly up but decided instead to buy another unit I found on ebay for $59. It should be here Tuesday and barring any bad weather I should have it all installed and going in a couple of hours. Thanks to all for the replies. This site can be an invaluable source of help.

    fuel_pump_assbly.jpg
     
  10. drrocka

    drrocka New Member

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    Also, thought you might want to see what we're talking about here so a couple of pics.

    rt_side2.jpg

    Side1.jpg
     
  11. LongIslandVFR

    LongIslandVFR New Member

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