Engine dies at 8500rpm. ??
My motor dies when it get close to 9000rpm, sometimes as early as 8k, other times it makes it to 9k, but never more. It will do this on the road or in neutral standing still. It just flat dies, no stumble, no hiccups, just like the key was turned off. It will start back up without having to turn the key off first.
At first I though it was fuel related, starvation. I've checked the pressure (42psi and it will hold it after the pump is off). I checked flow, I disconnected the line to the throttle bodies, stuck it in a can and let the pump run until it drained the tank (it was about 2/3 full). The volume was good and never let up until the tank was dry.
All my tests were on the road but I finally tried revving it to 9000rpm sitting still in neutral and it still died. This doesn't require much fuel so now I don't think it's fuel related.
The FI light isn't on and there are no stored codes if I run the self diagnostic in dealer mode 2.
The only other issue is fast idle doesn't seem to work right after starting when cold. Don't know if this is related or even normal. Sometimes it will die once after starting, maybe 10-15sec after, but the second time its started, it stays running. Eventually the idle speed starts to pick up, but not right away as you might expect.
Other than the above, it runs fine.
I though it might be the vehicle down circuit because I'd bypassed it with a resistor, so I reinstalled the original sensor sans pendulum, still dies.
I've also bypassed the PARE valve electrics with a resistor.
About the bike - It's a 2009 Verys powertrain (1078 miles) transplanted into a 09 KLR chassis. I used all the engine and electrical components from the Versys except for the headlight, turn signals, brake light and ignition switch. Other than those items, all the electical is connected as it was on the Versys. I've only put about 38mi on it since completing the project and I only rode the Versys around the block once before dismanteling it so I don't know if it was doing this when I bought it.
Last edited by KLRsys; 04-13-2013 at 10:23 PM.