2006 GT500ABS - Interesting Problem

[chrisrappl]

My Aprilia is set up with a Velorex 565 sidecar. The installation of the subframe required the permenant removal of whatever made up the belly pan or bottom enclosure of the scooter body work.

I've had the rig for a couple of years and put a few thousand miles on it with no problems.

A few weeks ago I got caught riding in a heavy downpour (1st time in the rain on this bike). The engine oil light came on, but the engine seemed fine. Since it happened right when the bike got soaked, I thought that it probably was a wet connection giving a false reading. The light went out in a minute or two and the engine ran fine. Oil and filter are new, clean and the level is full. This is a 2006, so I should not have a problem with the slow t-stat allowing gas in the oil which weakens the plastic oil pump gear.

Since then, the EFI light takes a little longer than usual to turn off, but the voltage regulation is fine.

My son borrowed the rig last Thursday to go to Bonaroo in Manchester, TN - about a 500 mile trip one way.

The bike ran fine, he had a great trip and concert. He started home on Monday morning. After about 80 miles he ran into serious rain. Half an hour riding in heavy rain, the engine oil light came on and the EFI light came on. He pulled over at a Big Daddy's fireworks and convenience station, filled up and tried to start the bike. The EFI light would not come on, the engine would turn over but not fire (probably no fuel being injected).

I unloaded 80 bales of hay, hooked the wagon to the truck and picked him and the rig up and brought them home. I'm charging the battery tonight before I do any troubleshooting. I'll check the secondary fuses behind the front headlight cover tomorrow.

My best guess at this point is that with the belly pan protection removed, something is getting wet that shouldn't and possibly causing a fuse to blow.

If anyone has any experience with this problem, I'm all ears.

Thanks

[tomd]

I thought they Dumped the Plastic Gear in 03 or so But Ive an 06 W no issues Last week some reason I chkd oil Smelled Very much like Gas.. 4K miles on oil . I Imed changed Driven about 80 miles guess chk again Belly pan plastic off no see much Fuse or Relay in Ft cover..

[IAGolem]

Your theory sounds correct. Since the EFI light is the most active, I'd check the circuit to it and the fuel pump first. I think you got the oil light because the cranking built up some (insufficient) oil pressure. I wouldn't worry about the oil pump - the plastic is better and should outlast the seals.

I'd also pot the good connections that you come across that are exposed to prevent more gremlins in the future. Water is the enemy of electricity.

Let us know what you find.

[tomd]

So theres no way to trim up thee pan and reinstall ove Side car tubes etc ? well any way your water would have to travel up about 10 inches to get level with elec stuff start relays at bottom of glovebox door lip but behind it..Fuel level sensors etc midway in tunnel etc Id wanna whip thru some water and whip front cover off and see if I see droplets in that area Fuse strip Battery and wiring are up there ..

[chrisrappl]

I have removed all the bodywork so everything should be accessible.

I tested all the fuses with a continuity tester.

I removed and tested every relay that I could find.

I opened and cleaned (spray contact cleaner) every connector that I could find.

When I turn the key on, all the indicating lights work properly with one exception. The EFI light does not come on and I do not hear the fuel pump.

The Aprilia workshopmanual that I have is titled "Scarabeo 500 Chassis" and dated 09/2003.

I seem to recall some manuals being available online. Is there another manual that includes a flow chart and troubleshooting guidelines?

Does anyone know what would keep the EFI light from coming on when I turn on the key?

Shouldn't I be able to hear the fuel pump run when I turn on the key?

Any thoughts or suggestions would be appreciated.

[chrisrappl]

The fuel pump tests OK @ 1 ohm. I am not getting power to the pump. Probably not to the injector either.

I'm starting to suspect either the dash or the ECU.

These could effect both the engine oil light and the EFI light circuit.

Ill try to get the dash apart tomorrow. I don't know how I would test the ECU other than replacing it with a known good unit.

[Rockynv]

Is this an Immobilizer equipped bike? The fuel injection, ecu, dash and ignition are all encoded to work together so if any one component in the system got so wet as to short it out it could prevent the bike from starting or after multiple events could cause the system to fail completely.

It could also be something more simple such as a ground wire connection to the frame that failed after getting wet multiple times so that the connection needs to be unbolted, cleaned and then put back coated with some dielectric grease.

[chrisrappl]

This bike is equipped with an immobilizer. It seems to be working properly; the light flashes every 3-4 secs with the ignition off and goes out with the ignition on.

The grounds that I've checked have been clean and tight. I wish I could find a wiring diagram that I could actually read.

[Bob Walker]

Have you checked to see if the fuel pump relay is getting power when you switch on the ignition. I seem to remember a forum member recently discovering water in their fuel pump relay. The relay was installed with the contacts up making for a perfect way for water to get into the relay.

[chrisrappl]

I have not. I have checked each relay for proper operation by applying an external 12v source to the coil contacts. One of my problems is not knowing which relay is which.

[Rockynv]

I have not. I have checked each relay for proper operation by applying an external 12v source to the coil contacts. One of my problems is not knowing which relay is which.

Just because they click does not mean that they are making good contact. Are you checking continuity at the load connections with a meter or just powering up the coils to see if they click?

If memory serves me correctly some have noted a relay that tends to get water in it since it is not oriented with the base facing down and have had to reorient it to prevent this type of issue from reoccuring.

[chrisrappl]

I have checked all the relays by applying 12v to the coil and reading the contacts with a multimeter. All of my relays are mounted so that the contact plug is facing down.

[Rockynv]

I have checked all the relays by applying 12v to the coil and reading the contacts with a multimeter. All of my relays are mounted so that the contact plug is facing down.

Then its follow the power untill you find the point where it goes in but does not come out.

[chrisrappl]

VIN #ZD4RTC0156S000103 - 3,809 miles



This scooter is set up with a Velorex sidecar.



The subframe attaches to the bottom rails of the scooter, so the belly pan bodywork is permanently removed. This may allow water to get in places that would normally be protected by the belly pan.



About two months ago I got caught in the rain for the first time ever with this rig. The engine oil light came on right when it started raining very hard and went out two minutes later when the rain stopped. The bike ran fine, oil is full and clean. No problems afterwards. Chalked it up to the sensor connection on the engine getting wet.



Two weeks ago my son took the rig to Bonaroo in Manchester, TN - about a 500 mile trip one-way.



The bike ran great with no problems.



It sat out in a camping area from Thursday to Monday and got rained on over the weekend.



On Monday morning, it fired right up and he started for home. About 50 miles into the trip he got caught in a torrential downpour. The engine oil light came on. He rode for 10 minutes with the engine oil light on until he could get to a gas station. As he was exiting the interstate, the engine oil light went off, the engine lost power and then regained power and the EFI light came on.



He shut it down, waited for the rain to pass and then was not able to restart the engine. It cranked fine but would not fire.



I picked him and the scooter up and brought them home (sixteen hours with a hay wagon behind me in the mountains).



I have removed all the bodywork.



Tested all the fuses with a continuity tester.



Tested all the relays by applying 12v to the coil and reading the contacts with a continuity tester.



Opened, inspected and sprayed contact cleaner in every connector I can find.



The engine cranks fine and the oil light goes out while it cranks.



The immobilizer blinks every three seconds with the key off and the light goes out with the key on.



When I turn on the ignition, all the lights come on except the EFI light and go off with the exception of the engine oil and ABS lights which stay lit.



The EFI light does not come on and the fuel pump is not getting power.



The day after I brought the bike home, when I had charged the battery and turned on the ignition, the EFI light flickered and eventually lit, but the engine would not start.



Now it is consistent - the EFI light never comes on.



I know that power is getting to the ECU. As a matter of fact it is always warm, even with the ignition off all night, it is warm to the touch in the morning. ???



I would like to troubleshoot the EFI circuit, but my shop manual is no help and I can't read the wiring diagrams (very small and fuzzy).



What would keep the EFI light from coming on?


I have checked the sidestand switch and the tip over switch for proper operation.


Ed and Micah have sent me e-mails and suggestions. If I was even within 1000 miles of AF1, I'd trailer the scoot to them, but alas, I'm too far away.


Is it possible that the ECU is programmed to disable the EFI after the oil pressure light has been on for 10 minutes?


Water penetrated the boot and connection at the engine oil pressure switch. Mixed with dirt and road salt, it lowered the resistance to ground and fooled the ECU into thinking the oil pressure was too low.


I really need to get the bike with the ECU to a shop with an Aprilia Naviagator and a tech who knows what he/she is doing.


I've contacted Scooter Nerds in Greensboro, NC and I'm waiting for their reply.


Any thoughts or advice would be appreciated.

[tomd]

Warm to touch HMMMM and where is this ECU in relation to the Reg/Rect??? or horn all my relays facing DWn to..look like New . None stay warm or seemingly energized.. Ive thee Red Key symbol flashin all time too Can see it from chair or bed It just sits there Ive had the battery out with key on engine off etc tryin to Fek up the computer just for the hell of it NOTTA.. Only thing I can tell ya is my transponder key will lite up the bike inserted only one way flip it over and it ll never lite up bike