Stalling problem solved? Seems that way.

MikeMike

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I've got an F650GS with a mid-2009 build date and pushing towards 50,000kms.
Since new, I have been living with the stalling problem. The local dealer (who controls a monopoly in this part of the country with the closest dealership with a different owner being about 450kms away) could find no problem under the warranty. "They all do that, senor", was the response.
Then, suddenly one day and without warning, my fuel pump controller failed (another story).
It was replaced with the black powdercoated newer version and presto! Hardly any stalling, about a 99% improvement.
I noticed when I gutted the old FPC, the upper socket, the black plastic one that fits into the controller, the contacts were merely piercing the solder on the little printed circuit board inside. Not really a cold joint per se, but a very odd effect where the solder was not "stuck" on the pins of the socket, it was merely touching them. Making contact but not adhering to the pins, the pins slid out of the solder pool.
Unfortunately, this is not something you can check as it requires you to gut the FPC from the bottom up and renders the part unusable except for the "roll your own" emergency bypass cable.
If you still have a stalling issue, it might be money well spent to replace the FPC and see if it works. If it doesn't, you are not entirely wasting your money as at least you'll have a spare if the new one goes or if someone else's FPC goes south during a group ride.
Just thought I would pass this on. At a $175 bucks a pop, you might think twice about the part swap, but you should at least educate yourself with the Tim Cullis emergency splice method to get yourself home (as I have mentioned before).
 
Interesting, not really heard of an FPC problem on these bikes.

Say it ain't so, Tim! You were featured in a starring role in "the other story".
A few members of the ADV forum paid special attention to your advice, too.:thumb

I have a sneaking suspicion that the stalling issue I had lived with all along was related to the solder job on the socket to PC board on the old controller. Who knows? I'm just glad it is gone, it was a real pain in the arse. But it is amazing how fast you can light the fires again, in Mexican traffic!:pullface
 
"They all do that, senor", was the response.....
... Now go to the dealer,ask for an owner/manager and stick that FPC into his arse just to realise to what sort of pain you've been through since 2009:rob.
 
Hi, I have an 09 f800 GS and it started stalling for no apparent reason. It is now in the garage and refuses to start. I now think it may be the fuel pump controller which I will try to bypass. I will let you know if it works.
 
If it cranks endlessly and doesnt fire and you have sufficient fuel in it, I will bet that is what it is. Bypass it and then assume the normal position of a Motorrad customer at the parts counter.
Use the old one to make a future use plug and play bypass cable which you can zip tie to your frame with a size 10 torx key.
If the one they offer you is black and shiny, buy it. If it is grey colored buy it somewhere else.
 
Thanks Mike,


Fitted a new fuel pump controller and bike fired on 1st push of button. I think this has been causing the stalling and was on its way out! :beerjug:
 
Be sure to keep that old controller and follow the instructions from Tim Cullis on how to roll your own plug and play by pass cable. Someone will thank you one day when you pull up and can solve their problem on the spot!
 


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