Electrical Troubleshooting help

[pvwheeler]

Hi guys,
I'm looking for a little help on troubleshooting an electrical issue |I am having with my 2010 GSA. The original issue was during winter layover, suddenly the right signal would light up (not flashing though) and it seemed like the heated grips were on, Both occurred imediately after turning the key on. I also noticed that the horn foglights, hi/low beams,ESA and info button also did nothing. I noticed these things during the first test ride in the spring.
The bike started and ran fine. I have tried two different batteries (neither of them new but worked fine in my DL650 (admittedly not a very fussy bike)
I tried a couple other things and I am not sure which fixed my problem temporarily. I repeatedly flicked the left turn switch (least likely) but also manipulated the wiring around the steering head after cutting off a bunch of cable ties that seemed tight. I cant see any rubbed through spots.
I took the tank off and have just done a quick inspection.Nothing jumps out at me. My right signal doesnt work. The cancel switch, and kill /start switch both work fine. Im not sure about the heated grips.Oh and my fuel level hasnt worked this season either,but thats not suprising even with the new improved strip.
I hooked up Motoscan and my only trouble codes are Fuel level sensor,heated handlebar grips , and esa hall sensor front. After clearing the only one to come back was the fuel level sensor (no tank installed either).
I can activate the right turn signal using motoscan.
I will get around to checking my grounds as well. Would the turn signal switch being constantly on stop anything else from working?
Could it just have been a bad switch?
Any help appreciated. I an familiar with regular wiring but I have next to no experience with canbus
On a related note the bike did have risers on it which I took off..
Thanks!
Steve

 

[Mistacat]

As you have not had a reply yet here are a few pointers.
The items that you are having issues with are controlled by the ZFE (Central vehicle electronics unit).
The items that you are not having problems with i.e. start run etc are controlled by the BMSK ( Engine control unt).
The turn signal switch L & R switch to a common ground.
Left to pin 20 Right to pin 54 on the ZFE.
As you seem to be having several problems relating to the ZFE ecu and as you have the tank off I would unplug the ECU for a few minutes hoping to reset it, but having changed the battery already I don`t have a lot of hope in this but worth a try. The ECU`s have live feeds to them which are not disconnected by switching off the ignition.
Hopefully someone with more experience will be along soon.

 

[pvwheeler]

As you have not had a reply yet here are a few pointers.
The items that you are having issues with are controlled by the ZFE (Central vehicle electronics unit).
The items that you are not having problems with i.e. start run etc are controlled by the BMSK ( Engine control unt).
The turn signal switch L & R switch to a common ground.
Left to pin 20 Right to pin 54 on the ZFE.
As you seem to be having several problems relating to the ZFE ecu and as you have the tank off I would unplug the ECU for a few minutes hoping to reset it, but having changed the battery already I don`t have a lot of hope in this but worth a try. The ECU`s have live feeds to them which are not disconnected by switching off the ignition.
Hopefully someone with more experience will be along soon.

Thank you!

 

[pvwheeler]

So the microswitch should cause a ground on pin 54 to activate the turn signal?
Is that correct?
Thanks!
Steve

 

[squibb34]

Left hand switchgear possibly?

........ https://www.ukgser.com/community/threads/switchgear-fix.281401/

 

[pvwheeler]

Left hand switchgear possibly?

........ https://www.ukgser.com/community/threads/switchgear-fix.281401/

Thanks!

 

[Mistacat]

So the microswitch should cause a ground on pin 54 to activate the turn signal?
Is that correct?
Thanks!
Steve

Yes the microswitch should cause a ground on pin 40 on the ZFE not 54 as I stated earlier attached diagram.
Right and left hand indicator switches look to use different grounds, might be a clue there.

 

[pvwheeler]

Awesome thanks

 

[pvwheeler]

Well, good news and bad news... My turn signal worked once, after turning the key on today. never worked again. I have a ground on pin 40 when pressing the turn signal button.
after reinstalling the connectors on the ZFE and whatever is below it, I am now back to neither side of the handlebar controls working. I cleaned up the ground to the engine on the left side under the tank. Any idea where the others are located?
I may buy a new battery to try just in case. I really dont want to buy a ZFE if I dont HAVE to...

 

[Mistacat]

There are 2 more grounds on the engine located behind each cylinder under the intakes / injectors cant remember off hand if they are just for the coil /lambda sensor circuits but worth checking.

 

[pvwheeler]

Thanks!

 

[Santa-2512]

You mention that you were cutting cable ties around the headstock ,

But didnt notice any rubbed through spots ..

The early models suffered broken wiring within the looms at points around cable ties to the frame

When you get to the ZFE & BMSK try doing some continuity tests also,, if you have wiring with no continuity

You may have breaks within the loom , stripping and checking is the only way i'm afraid

The good news , is its all fixable

 

[pvwheeler]

Here's hoping! Thanks for the reply

 

[pvwheeler]

Well tried the easiest thing, brand new lithium battery. No improvement. Before I changed the battery I noticed I was back to the original problem...only the kill/ start switch working as far as handlebar controls....wiggling the wires doesn't seem to help. Maybe get back at it next weekend. Good thing I still have the WeeStrom lol

 

[botus]

in case it helps - the left switch gear depending upon bike spec are not all the same / interchangeable - weirdly either due to incompetence, cheap ZFEs or deliberate subterfuge, each button can be wired differently between various toy specs

so

A bike with No trip computer and no ABS, vs one with three separate buttons, can have each button create a differing signal back to the ZFE. e.g. Info button and ABS. Each button can operate differently (with a different CAN signal created). Like wise ABS and ASC on the same button, thus allowing the other to now become an ESA button wire each button to create yet another bunch of CAN signals

Because they are all playing weird beard CANbus silliness - Features, when swapping switchgear might not function anymore - They are NOT just on off signals from a given switchgear position....

 

[pvwheeler]

Yikes lol.
Thats helpful. This one (2010) has abs but no asc. I kind of wondered how they did that,(ASC/ABS on one button like my 08 )
I never did have much luck proving my left side switchgear using continuity the other day. right side was good. I also confirmed continuity for ground and power to the ZFE (constant and switched)
I'm using my Haynes manual wiring diagram, but having issues figuring that out too. Wiring colours (stripes or bands?)and deciding which connector to find the pin on mostly.
Usually its the one that actually has a connector in the proper place lol.
I am about to try a hail Mary and pick up a used ZFE from an 09 GS( if its under $200) and try my luck, hoping the Motoscan tool can help as well. I have read the odd story about them working although most dont.
A new ZFE is $1300 CDN so I think I would be lucky to get my bike back for $2000. Assuming that is even the problem.

 

[botus]

I am about to try a hail Mary and pick up a used ZFE from an 09 GS( if its under $200) and try my luck, hoping the Motoscan tool can help as well. I have read the odd story about them working although most dont.

? what bit the ZFE or a the Motoscan app ? if its the app playing up - its the nasty dongle, the app works OK

don't forget you need the correct ZFE to suit the bike - I don't know if ANY of the correct type just fit - I suspect the hardware of a ZFE High is the same - but an RT will likely get a different version of software as it has certain stuff a GS doesn't, like cruise, heated seats and a silly elecy screen

and whilst coding is simple with the correct tools .... if that software release is missing bits, its missing bits - plus as per another thread recently, the VO (vehicle order) whilst not unique to a specific bike - it is specific to the toy count that bike was build with....

 

[pvwheeler]

No my motoscan is fine. I'm thinking my zfe might not be. The zfe I'm looking at is from a 2009 GS., mine is a 2010 GSA . Both have ESA, heated grips and abs . I haven't received an answer yet if the donor had ASC. Mine doesn't. No cruise or heated seats on either of course

 

[botus]

you can add ASC if you like - its a buyable option... the only hardware required is the left switchgear - and that's not required for the feature to work - just to toggle off, boring or sensible modes

ASC is an example of a toy that needs to be in the VO for comms to get round the bike - you can enable in modules but without the VO it will not operate
(should have a matching VO in the DME, ZFE and Cluster) I suspect ASC in the ZFE wouldn't be an issue... unless the order matters...

When ASC was retrofitted on my old late 2007 bike - non factory Options sit at the bottom of the VO lists out of number order
same with an alarm module that too sits at the bottom - on another BM bike I have

 

[pvwheeler]

Hopefully it doesnt matter, but as I said I wont be shocked if it doesnt work. but if it does something different at least I know I HAVE to go to the dealer.
Thanks for your help BTW!
Steve