The Yamaha Road Star Warrior Forum

Took my 05 warrior out for a spin tonight and low fuel light came on. After 5 miles of riding light started flashing 8 times over and over agian (code 8?). Pulled into gas station, filled her up and light still flashed all the way home. I did a search and seems like bad connection is most common cause. Any ideas where to start looking first??

Thanks

Update: After checking wiring and dry breaks, isolated fault to fuel pump sending unit, resistance too high (almost open circuit). Sending unit only serviced by replacing fuel pump assembly ($500.00). Replaced fuel pump and it fixed the problem. Thanks to all for your help with this very unusual problem.

Try the two dry breaks. One is under your seat, the other is beneath the left side AIS cover. Make sure they are pushed all the way in until you hear them click.

What are the Dry Breaks, are these the connectors that allow the removal of the tank without first draining it?

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Originally posted by mat4uscg

What are the Dry Breaks, are these the connectors that allow the removal of the tank without first draining it?

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Exactly []. Pull them completely off and then try to reconnect both of them. You should hear an audible "click" on both when you reattach them.

By the way, the fuel light flashing 8 times in a row doesnt mean code 8. There isnt an error code 8 (it doesnt exist). It was just coincidence. It sounds like it could be a dry break issue. The light flashing 8 times is just a fluke.

Hope this helps!!
Dave

Just curious if next time you rode it did it clear itself out or is it still flasing? Did you notice when you gassed up if you over-filled the tank right up to the cap? Just wondering.

quote:

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Originally posted by cornholio

Took my 05 warrior out for a spin tonight and low fuel light came on. After 5 miles of riding light started flashing 8 times over and over agian (code 8?). Pulled into gas station, filled her up and light still flashed all the way home. I did a search and seems like bad connection is most common cause. Any ideas where to start looking first?? Thanks

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Try doing a diagnostic check, here's how:
ENGINE CODES:

11 - NO SIGNAL RECEIVED FROM CYLINDER IDENTIFICATION SENSOR (CAM POSITION SENSOR)

12 - NO CRANK POSTION SIGNAL

13 - AIR INTAKE SENSOR #1 - OPEN/SHORT DETECTED

14 - INTAKE PRESSURE SENSOR #1 - PIPE CLOGGED OR THROTTLE POSITION SENSOR (TPS) STUCK

15 - TPS - OPEN/SHORT DETECTED

16 - STUCK TPS SENSOR

19 - SIDE STAND SWITCH - OPEN/SHORT DETECTED

20 - ATMOSPHERIC SENSOR VOLTAGE & AIR INTAKE PRESSURE SENSOR VOLTAGE DIFFER GREATLY

22 - AIR INTAKE TEMP SENSOR - OPEN/SHORT DETECTED

23 - ATMOSPHERIC SENSOR - OPEN/SHORT DETECTED

25 - AIR INTAKE PRESSURE SENSOR #2 - OPEN/SHORT DETECTED

26 - INTAKE PRESSURE SENSOR #2 - PIPE CLOGGED OR THROTTLE POSITION SENSOR (TPS) STUCK

27 - OIL TEMP SENSOR - OPEN/SHORT DETECTED

28 - ENGINE TEMP SENSOR - OPEN/SHORT DETECTED

29 - DECOMPRESSION SOLENIOD (THERMISTOR) - OPEN/SHORT DETECTED

30 - MOTORCYCLE HAS OVERTURNED

37 - FAULTY LINEAR CONTROL VALVE

38 - DECOMPRESSION SOLENOID - OPEN/SHORT DETECTED

41 - LEAN ANGLE CUT OFF SWITCH - OPEN/SHORT DETECTED

42 - NO NORMAL SIGNAL RECEIVED FROM SPEED SENSOR & OR NEUTRAL SWITCH OPEN/SHORTED

43 - ECU CAN NOT MONITOR BATTERY VOLTAGE - OPEN/SHORT DETECTED

50 - FAULTY ECU MEMORY







HOW TO PERFORM INDIVIDUAL SENSOR CHECKS, SET UP

- REMOVE SEAT & FOAM THING

- PRESS & HOLD SELECT AND RESET BUTTONS WHILE TURNING KEY ON, CONTINUE TO HOLD BUTTONS FOR APPROXIMATELY 8 SECONDS

- DIAG APPEARS IN THE CLOCK AREA OF THE INSTRUMENT PANEL

- RELEASE BUTTONS, PRESS & HOLD SELECT AND RESET BUTTONS AGAIN FOR APPROXIMATELY 2 SECONDS

- DISCONNECT FUEL PUMP CONNECTOR - LOCATED UNDER THE LEFT REAR CORNER OF GAS TANK. FUEL LIGHT ON INSTRUMENT PANEL WILL FLASH, THIS IS OK.

- INSTRUMENT PANEL WILL DISPLAY:
CLOCK SECTION: DI 01 (THIS IS THE 1ST DIANOSTIC CHECK)
ODOMETER SECTION: A NUMBER, USUALLY 15-17 (THIS AREA SHOWS THE VALUE OF THE SENSOR)

PERFORMING SENSOR CHECKS
( SELECT BUTTON WILL SCROLL UP, RESET BUTTON WILL SCROLL DOWN THRU THE CHECKS )

- DI 01 - THROTTLE POSITION SENSOR: TWIST THROTTLE, VALUE = : CLOSED =15 - 20, OPEN = 95 - 100.

- DI 02 - ATMOSPHERIC PRESSURE SENSOR: VARIES DEPENDING ON ATMOS. PRESS FOR THE DAY

- DI 03 - AIR INTAKE PRESSURE SENSOR #1: VALUE = 10-200 MMHG

- DI 04- AIR INTAKE PRESSURE SENSOR #2: VALUE = 10-200 MMHG

- DI 05 - INTAKE TEMP: MEASURE WITH TEMP GAUGE, COMPARE TO VALUE ON DISPLAY

- DI 07 - SPEED SENSOR: VALUE = 0-999

- DI 08 - LEAN ANGLE CUT OFF SENSOR: VALUE = 0.4 - 1.4 VOLTS

- DI 09 - FUEL SYSTEM VOLTAGE: VALUE = 0 - 18.7 VOLTS (12 VOLTS NORMAL)

- DI 10 - OIL TEMP SENSOR: VALUE = -30 TO 200*C / -22 TO 392*F

- DI 11 - ENGINE TEMP SENSOR: VALUE = -30 TO 200*C / -22 TO 392*F

- DI 20 - SIDE STAND: VALUE = ON/OFF

- DI 21 - NEUTRAL SWITCH: VALUE = NEUTRAL - ON, IN GEAR - OFF

- DI 30 - IGNITION COIL #1: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK ENGINE LIGHT SHOULD FLASH 5 TIMES.

- DI 31 - IGNITION COIL #2: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK ENGINE LIGHT SHOULD FLASH 5 TIMES.

- DI 36 - INJECTOR #1: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK ENGINE LIGHT SHOULD FLASH 5 TIMES WITH A CLICKING SOUND.

- DI 37 - INJECTOR #2: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK ENGINE LIGHT SHOULD FLASH 5 TIMES WITH A CLICKING SOUND.

- DI 50 - FUEL SYSTEM RELAY: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK ENGINE LIGHT SHOULD FLASH 5 TIMES WITH A CLICKING SOUND.

- DI 52 - HEADLIGHT RELAY: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK ENGINE LIGHT SHOULD FLASH 5 TIMES WITH A CLICKING SOUND.

- DI 54 - LINEAR CONTROL VALVE: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK FOR ACTUATION (CYCLING) SOUND.

- DI 55 - DECOMPRESSION SOLENOID: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. CHECK FOR ACTUATION (CYCLING) SOUND.

- DI 60 - E2PROM: VALUE = 01 - 02 FOR CYLINDER MALFUNCTION. 00 = NO MALFUNTION.

- DI 61 - MALFUCTION HISTORY: VALUE = 11 TO 55, 00 = NO MALFUNTION.

- DI 62 - MALFUNTION HISTORY ERASE: 00 TO 21, 00 = NO MALFUNTION
TO ERASE HISTORY: TURN ENGINE STOP SWITCH TO OFF THEN BACK ON. DISPLAY SHOULD READ 00.

- DI 70 - CONTROL NMBER: DISPLAYS THE PROGRAM CONTROL NUMBER, VALUE = 00 - 255.

Rode in to work today and the low fuel light still flashes 8 times over and over the entire 45 minute ride in. Unfortunately it did not resolve itself, I'm not that lucky with my stuff.

quote:

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Originally posted by cornholio

Rode in to work today and the low fuel light still flashes 8 times over and over the entire 45 minute ride in. Unfortunately it did not resolve itself, I'm not that lucky with my stuff.

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I had my fuel light on when the dry break under the seat was not connected fully.

But is was a steady light, not blinking. Sorry thats not an answer, just helping eliminate something.

Light still flashes, comes and goes now, flashes more often than not. Found a schematic, very poor quality compared to Ford manuals that I'm used to but I think I can figure it out. I need to pull off seat, head light and tach and do a thorough check of fuel sender circuit. I'm sure there is a bad electrical connection somewhere, I'll post up what I find. Thanks

wow, did you ever reseat the dry breaks?

Ok, haven't checked the dry breaks yet, haven't had time to do anything yet. This maybe a stupid
question but, is the fuel pump and sender wiring part of (built into) the fuel dry breaks???

Save the wear and tear on your keyboard and go check the dry breaks. That's been suggested by four people. They are most likely right. That's also what you found from your search. Wow, listen to them [8D]

Yea... what arwarrior said. I did a bunch of mods to mine at 3 miles, and the fuel light came on at 87 miles...rear dry break wasn't all the way down...It looked like it and it felt like it, but I released it and pushed it together and it clicked like everyone has told here. Next tank I got 140 miles, If the flow isn't good for both dry breaks you'll get feul light symtoms...It wont take you long or cost you anything to try it. I am a mechanic too, Don't get caught overcomplicating a repair...lol Been trapped in that game a few times in my career...

Ok, I will check dry breaks first thing this weekend when I get a chance to work on it. Spare time for working on the bike is hard to come by for me. Just picking your brains for all info I can get and learn from it. I haven't had time to work on it since it first started flashing the low fuel light last Sunday night. I appreciate any help ya'll give me. Thanks.

Hurry up so we can all give you an "I TOLD YOU SO" []