GS911 over-voltage fault R1200GS

sevenfifty

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Hi, I've got very strange electrical problem and need your advice please.
When key is ON everything works fine - blinkers, high beam, horn etc
Just after i push the starter button and engine start working all disappear - no blinkers, no high beam, no horn, no heated grips, i can't change the trip computer also. Handlebar controls just doesn't works.
Only low beam works and that's it!


Luckily I have a GS 911 and the following error fault was reported:

Fault Codes Report

41758: Battery Positive (KL30) over-voltage
This fault occurred 31 times.
The fault is currently present.


Also apply screenshot that shows that according live data ZFE voltage values are too high when the key is ON and the engine is not running.
How could it be to show so high voltage until the engine is not running?
Please help with this weird problem!

Thanks in advance!

036713141.jpg
 
Battery voltage at 17.47v is a serious over charge and without control unit intervention would boil the battery and damage stuff
Looks like you have a failed alternator
 
Hi, thanks for your answer

Maybe it was not explained too clear in my first post but the screenshot was made when engine is not running only ignition key "ON"

When I check the battery with engine OFF voltmeter reading is around 12.5-12.6v

When the engine is running voltmeter shows 14 - 14.2v and I've never seen higher values

Everything seems fine but GS 911 still is reporting over-voltage fault
 
If the battery voltage really is OK then I would point the finger at the ZFE unit. The conditioning circuit for either the power supply or battery volts input has went South. I don't know in this case but most controllers actually work on 5v and a circuit clamps the voltage down to this. If a component has failed then it will see the the wrong voltage and the maths inside it will report it as wrong.

Make sense?
 
Try checking the obvious stuff first, such as the possibility of high resistance contacts e.g. a loose or corroded earth connection somewhere or a loose battery terminal.

Maybe disconnect the battery and try undoing the multi plug on the ecu and reconnecting everything again.
 
Today i removed the tank in order to check alternator terminals, belt and other connections but still the same fault exist

I know that so high voltage could boil and damage my battery, also my bulbs and lights should blow. I tried to swap battery with another one from friend's bike and still the same.

Also when i do diagnosis with GS 911 it shows normal battery voltage always around 12.4-12.6v as you can see in the attached screenshot.

I suspect fault in ZFE in my opinion ZFE misread the voltage values ( don't know if it's possible ) and shuts controls to prevent damage. Is there some way to check and see is it working properly or some way to restart/flash it?

I see many ZFE for sell in ebay so is it possible to replace it and do i need the new one to be re-programmed ?

Thanks for your time and replays!
 
Be wary of buying ZFE's off eBay. I think they might be bike specific depending on your factory options. I bought a new one from BMW recently and had to have the info on the old ZFE transferred to the new one before it would work properly.
Have a look HERE
 
What voltage is the GS911 showing with the engine running?
 
My system voltmeter shows up to 14.4 volts when running and about 12.6 battery alone. This is normal and wont harm the battery. Anything higher with engine running will suggest the alternator voltage regulator is faulty.

The most reliable voltage test is with a voltmeter connected across the battery terminals and ride the bike.
 
Bendy toy said:
My system voltmeter shows up to 14.4 volts when running and about 12.6 battery alone. This is normal and wont harm the battery. Anything higher with engine running will suggest the alternator voltage regulator is faulty.

The most reliable voltage test is with a voltmeter connected across the battery terminals and ride the bike.
Click to expand...

That should have been 14.2V not 14.4V
 
Thanks SteveM, i will continue investigates the problem for now. If decide to order new ZFE i'll go to my local motorrad dealer. Thanks
 
Update

Hi all, the new battery was installed Exide YTX14-BS just to be sure the problem is not in battery

The fault code in GS 911 still exist

1 fault code found:
41758 Battery Positive (KL30) over-voltage
The fault is currently present.

I think ZFE somehow read wrong voltage and cut controls after engine starts - no blinkers, no horn, no heated grips
GS 911 shows extremely high input signals for voltage and in the same time voltage is 14.31v ( I also checked it with multimeter )

036753148-big.jpg




When I check the Engine module and Realtime values in GS 911 it shows completely normal Battery voltage 14.3V, just what I find with multimeter, so I don't think alternator or battery is a problem.

Any ideas?


036753152-big.jpg
 
You measured the voltage across the battery, and it was fine. Why then did you change it?
The fault exists when the engine is not running, so it can't be the alternator or anything to do with the charging circuit.
Looks like its your ZFE unit.
Have you tried disconnecting and reconnecting the battery?
Might just need resetting.
 
I know that servo ABS models are very sensitive to battery condition. My old battery was 4+ years old, so i decide to replace it in order to be sure it's fine.
Yes, battery stayed overnight disconnected but no luck, i also disconnected, sprayed with Contact cleaner and reconnect ZFE plug

The weird thing is everything works fine (blinkers, horn etc.) when key is ON and fault still exist, but stops just after engine starts

Also if start the engine with right or left blinker on then i can't stops it until i switch off the motor, so I suspect ZFE to cut communication to all controls when engine run.
 
I think you need to start preforming volt drop checks across primary battery leads maybe there's a high resistance somewhere.
maybe in the earth circuit.
There are YouTube clips showing how to carry out volt drop checks
 
Can you borrow an ZFE? If the replacement works you know its the unit but if not you could avoid a costly mistake.
 
Update:

Problem was resolved. It seems bad alternator was the reason for this weird problem. Bought used one from ebay and changed it. Now everything is just fine - no more overvoltage reading and all controls working.

Thank you all for your help!




Sent from my D5803 using Tapatalk
 
Thanks for the feedback, it will probably help in future if this rare fault reoccurs on somebody else's bike.

It might be worth getting your old alternator repaired and keep it as a spare, it could be as simple as a failed diode. They cost a small fortune from BMW.
 
It's a common fault. Alternator regulators fail. The bike is no different.

The alternator is easy to test. Any half decent motor sparky will do it for next to no cost.
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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