M796, Serious issues after Re-Flash.

Rxmfn7 · July 21, 2011, 06:00:05 AM

Hey guys. First post here, but could use some help. I recently purchased a new 2011 M796. It has ~1500 miles on it now, at which point I wanted to do some basic modifications. I purchased an S-C Project full 2-1 Exhaust, K&N Filter, and had sent my ECU out to Moto-Lab for a reflash. Yesterday I get the ECU back, and after re-installation, the bike has serious issues. It will idle, but is dumping fuel out of the exhaust. I mean, literally.. within 30 seconds of idle there is a sizable puddle on the ground, and you can see it gushing out of the slip fittings of my exhaust, as well as right where the exhaust meets the head. I thought it was oil at first , because towards where it comes out the end of the exhaust its black and thicker, but I think it may just be fuel mixing with the carbon in the exhaust? At any attempt to rev, it will pop, backfire, and stall. As well as blow out a good amount of smoke. I have contacted Moto-Lab, he suggested that it could be a TPS needing reset. I know these Siemens ECUs have an autoreset for the TPS every time you start it, but I still cycled the ignition 3 times to give it a full reset, all of which didnt help at all. He said they have never had any issues with any of their tunes. So my question here, is there anything else, that I possibly could have done that would cause these issues? I will post a few pictures, as well as a short video (sorry if video is not viewable, its from my FB account). Any help would be greatly appreciated.

Click Here for Video: http://www.facebook.com/video/video.php?v=259134814101197#

bikepilot · July 21, 2011, 07:26:34 AM

I don't have any 796-specific experience, but the only thing I can think of that would cause that much excess fuel to dump in other than a really bad map/ecu would be an injector stuck wide open or, maybe, super-high fuel pressure. Given that you haven't messed with the injectors or fuel pump/pressure regulator (if the 796 uses one - I dunno), my money is on a screwy map, maybe it got corrupted during the flash or something.

Its also possible some sensor is super-far out of whack, but i'd guess that you'd get some sort of trouble code if the ECU saw a sensor reporting, say WOT throttle all the time or that the air temp ws -100 deg F for example. The easiest test would be to plug in a known-good, stock ECU and see what happens.

Good luck!

Slide Panda · July 21, 2011, 07:29:31 AM

Your video link doesn't work. It was truncated, the ... was replacing something.

Rxmfn7 · July 21, 2011, 07:34:28 AM

Thank you for the reply. Swapping out to a factory ECU was my first thought, unfortunately I dont have one being my stock one has been reflashed. Im trying to find a local forum where perhaps someone would be kind enough to lend me one to try out. Literally all I did was unbolt the tank and prop it up, disconnect the battery and remove the ECU. No other lines,sensors, anything have been disconnected. It was down for nearly a week while the computer was out, and when I got it back plugged it in, hooked up the battery, and now this. So, logic says it just about has to be the tune.. but I mean from the amount of fuel flooding out it would have to be pretty damn far off I would think. I just wanted to get some others opinions, because as I said the response I got back was "We've never had an issue with that flash". It makes my heart sink seeing my brand new bike turn into a paperweight.

Rxmfn7 · July 21, 2011, 07:37:12 AM

Sorry, should work now.

Quote from: Sad Panda on July 21, 2011, 07:29:31 AM
Your video link doesn't work. It was truncated, the ... was replacing something.

DoWorkSon · July 21, 2011, 09:02:54 AM

Did you move the tank at all removing the ecu? I know you have to move it up to get to ecu... Possibly you loosened up a line to the fuel pump, which sits directly above where the fuel appears to be coming from...

Rxmfn7 · July 21, 2011, 09:11:52 AM

Thanks for the reply. Yes the tank was moved slightly, just to access the ECU. However Im very sure no lines were pulled. Also, you can physically see the fuel is pouring out of the exhaust, nowhere else external.

Quote from: DoWorkSon on July 21, 2011, 09:02:54 AM
Did you move the tank at all removing the ecu? I know you have to move it up to get to ecu... Possibly you loosened up a line to the fuel pump, which sits directly above where the fuel appears to be coming from...

Langanobob · July 21, 2011, 09:57:57 AM

The evidence at this point is pointing at their re-flash job, although as things go, it could be something unrelated. I think I'd get back on the horn with Moto-Lab and as politely as possible request a higher level of customer service. If they are smart enough to re-flash ECU's it seems like they might be smart enough to be able to suggest some troubleshooting procedures that would determine if it actually is their ECU work that's causing the problem.

Good luck.

Rxmfn7 · July 21, 2011, 09:59:53 AM

I have contacted Moto-lab, he said they have asked higher up and are awaiting a response. In the meantime, I just wanted to be completely sure it was nothing else that could be causing these issues.

thought · July 21, 2011, 11:36:22 AM

yeah, i would say send it back to them and have them reflash it again.

but... before you do... with a easily fabbed up mount and a lighter... ducati monster 796 flamethrower edition. haha, you can get the batman turbine effect.

2-Skinny · July 21, 2011, 12:13:40 PM

It appears that fuel is running down the exhaust, not out of it...

Rxmfn7 · July 21, 2011, 12:20:11 PM

See picture #2, that is looking up from the gound at the "Y" pipe where the 2 exhausts merge into one. Right at that slip fitting fuel is pouring out. Also picture number 3 is exhaust into muffler, also where fuel is coming out. The 3rd picture, where fuel is on the crankcase, is coming straight off the rear head-exhaust connection (apparantly I needed to snug up the bolts a bit more). You can stick your head under the tail and see fuel physically pouring out the exhaust port of the head. Also in the video, you see all of the smoke (Unburnt fuel) shooting out when its attempted to be revved.

Quote from: 2-Skinny on July 21, 2011, 12:13:40 PM
It appears that fuel is running down the exhaust, not out of it...

Raux · July 21, 2011, 12:22:11 PM

you know what...
why don't you check the return fuel connector.

Howie · July 21, 2011, 12:32:01 PM

Quote from: Raux on July 21, 2011, 12:22:11 PM
you know what...
why don't you check the return fuel connector.

That could do it.

2-Skinny · July 21, 2011, 12:42:08 PM

Quote from: howie on July 21, 2011, 12:32:01 PM
That could do it.

I thought that too- may have come off of tank connection...and just "looks" like it is coming out of exhaust....

News:

M796, Serious issues after Re-Flash.

Raux