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Messages - kbosak

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1
Venox 250 / Re: What is proper reset procedure for ECU errors
« on: May 10, 2020, 12:49:40 PM »
I have completely disconnected ECU fo several hours so it shoudl have been reset.
I am afraid now that ECU is broken.

Of course it has ECU and its code is 3920A-LBF2-E00 or similar.

2
Venox 250 / What is proper reset procedure for ECU errors
« on: May 09, 2020, 08:33:42 PM »
My problem is that service manual was written by drunken idiots and I am guessing what they might have meant.
Accordign to Service manual,
error code readout is simple and it works:
-key position off
-throttle full
-key on, engage ignition switch
-led is lit for 2s, then 3 s off, then on again and
-at that moment you have to release the throttle

Readout starts, and I got all error codes listed what this motorcycle ever had. Several of them are completely fixed, for example relays are up to spec under load, 100% sure, and yet I am failing to reset the codes.

Let me quote error readout procedure that WORKS:
"
SELF-DIAGNOSTIC PROCEDURES
STEP-1
“key OFF ”? The throttle should be open and
hold fully
STEP-2
“key ON ” ?the CELP lamp will light for two
second then off.
Waiting for the CELP lamp again light
The throttle should be close.
The CELP lamp will to start output failure
Signs.( failure codes to use of long?short lamp to
collocate glisten showed)
When more than one failure occurs, the CELP
lamp shows the codes in the order of lowest
number to highest number. For example, if the
indicator blinks once, after code off 4 seconds
and comes on 4 seconds, then blink 2 times, two
failures have occurred. Follow codes 1 and 2.
"


Now there is reset procedue I have problem understanding, since it does NOT WORK:
"
CLEAR- FAILURE CODES PROCEDURES
STEP-1
You should be failure parts or Sensors to
exclude. .
STEP-2
“key OFF ”? The throttle should be open and
hold fully
STEP-2 :o
“key ON ” ?the CELP lamp will light for two
second then off.
Waiting for the CELP lamp again light
The throttle should be open and hold
fully.(waiting for 10 seconds?)
The CELP lamp don’t output failure codes.
Finish. Clear failure codes procedures
"


My approach was simply from the above, that I have turned key and ignition on, then basically held throttle open at least 10s after second CELP lamp on. But then nothing, silence, and readout of codes returns all again.
Any clues how to clear the codes? Already tried disconnecting ECU for a long time. I suspect it uses FLASH or FRAM memory.

BTW my error codes are:
02
03
04
05
08
10
31
34
37
38
51
51
61
62

Basically with this amount of errors this should not even start (errors for relays: fuel pump, ignition, battery voltage, sensor voltage, idle throttle sensor, TPS, fan relay, ingition driver circuit, ISC valve, camshaft position, footrest). And yes fan is workign fine and enables when hot, motorcycle runs very well without overheating, I am maintaining it since 2 years but at last I would like to hunt all remaining problems.

Any idea howto?

Note: this is not that ECU is stupid and has random mix of errors, for example ignition errors concern only front cylinder and not rear one, and the mortorcycle truly had ingnition problems on the front cylinder initially two years ago.

3
Hi,
I live in Poland and trying to bring post-Italian Venox to perfect state. For sure this is not canister, which is responsible for filtering out the fuel tank air inlet/vent. This part is pumping fuel into the system aided with electrical supply and air pressure taken from somewhere. I am sure late EFI and carburetor fuel system differ significantly.

4
Hi everybody.
Picture in attachment. The mechanic told me I can improve idle response during hot weather after replacing this part.
This is a brass-colored cylindrical pump with 3 tubes going into it.
I did not managed to get part number of this item, does not appear on parts manual I got.
Could anybody tell me where to find it, and what is official Kymco name for it (or part number) (they use broken English all the way)?

5
Venox 250 / Re: Trying to identify black box said to be faulty: KYC-D421
« on: September 06, 2018, 08:39:32 AM »
I think I know why it is there, as an engineer in embedded electronics. I think reverse voltage fed by free-spinning fan was inducing noise on ground wires (-) that they suspected was frying their voltage regulator which was then overcharging batteries which had then troubles delivering voltage under load leading to starting problems and even unreliable ignition. While the source of the problem is narrow hysteresis and the number of on/off cycles for the fan when it works, having as much as 30% of its life spent as free-spinning flywheel generator.

The other problem is, if the mechanic pointed at this part as a reason of unreliable idle and fuel flow at high temp, I am starting to doubt about his skills as he misunderstood KYC-D421 for something related to ignition.

What I did not understand, why entire family of KYC-D421 has so many versions and even incompatible plugs and wiring without additional information. Additionally I have no confirmation if KYC-D421 I see in my motorcycle is indeed EMI FILTER FAN MOTOR 39100-KHD8-9000 - on the partlist manual it loooks.. different.

6
Venox 250 / Trying to identify black box said to be faulty: KYC-D421
« on: September 05, 2018, 06:33:52 PM »
It is mounted under plastic fairing on the left side, it is a black box 1x1x2 inches.
Mechanic said it is suspected and called it interruptor, I see similar items on EBAY called relay. However, those have mounting hole and one more pin used in the plug - they are different.
The problem is I cannot find it on electric diagram, and commonly sold parts with identical marking have one less pin in the plug socket, a mounting hole for screw and are incompatible with my Venox. What is going on, I have something not mentioned in wiring diagram:
https://www.kymcopartsmonster.com/oemparts/a/kym/5b50e86487a866110c2e089f/wiring-harness-electrical-components
Could it be
EMI FILTER FAN MOTOR ?
39100-KHD8-9000

If so, it is completely unrelated to idle throttle...

7
Venox 250 / Venox 250i (EFI) need operational fuel pump
« on: September 05, 2018, 03:02:40 PM »
Hi,
after several trials to fix the problem by pro mechanic,
after cleaning fuel lines, I still have idling problem and occasional 'delayed rpm and uneven acceleration' problem when the weather is hot and the engine is very hot.
The problem is worse at high temperatures, less problematic when fuel tank is full.
Opening the tank is not stopping the rough idle when engine is hot.
One mechanic disconnected fuel lines from fuel pump and said that at first place, the pump is developing unreliable and low pressure.

So it looks a fuel pump. Now the problem is I cannot even find part number, yet alone a pump for sale. As I understand it is mounted inside fuel tank itself, but all the schematics I have do have only elements I would say are typical for earlier carburetor version. Unless I don't understand something.

For example here:
https://kymcopartsonline.com/catalog/search_diagram_detail.php?s_fk_manufacturers_id=21&s_fk_model_year_id=1&s_fk_scooter_model_id=31&s_parts_diagram_id=842
I see 37800-KED9-900 Fuel Unit. Is this the fuel pump?

EDIT: This looks like fuel level metering unit.
Either in section canister:
https://www.kymcopartsmonster.com/oemparts/a/kym/5b50e76187a866110c2e0873/canister

Then fuel pump would be 
17310-KED9-M30 (but I think this is a carbon-filled filter for gas tank venting)
or
1880A-KHD8-91A (AI/C-AICV ASSY but some searches indicate it is secondary air filer? omg&wtf?)
or
https://www.kymcopartsmonster.com/oemparts/a/kym/5b51e77787a8660d78cad49a/fuel-tank
1695A-KED9-900 (AUTO COCK ASSY FUEL - but this look some ass-designed valve not a pump)

I am lost.


8
Venox 250 / Re: Upper exhaust much cooler than lower one
« on: September 05, 2018, 02:52:15 PM »
Thank you for the suggestions. It was an indication of unreliable wiring to one of the cylinders, which was not firing correctly. One day I rode on paved road and it died during moderate riding (the second cylinder could not keep the motor spinning below some 2000RPM). Local mechanic was surprised by mess+entanglement but fixed the problem. The problem didn't re-occured for the next 2 months.  Upper exhaust is still cooler than bottom one, but the difference is much much less than before. I was learning to drive and not sure what dynamic to expect, so I didn't raeliazed the problem at first place.

9
Guys, I have changed my default setup in front from
Dunlop K555 120/80-17 Radial to Michelin Road 4 120/70-R17 Radial (noticed light stiffness increase, but since Venox front was very soft, it is acceptable and I like extra wet traction).

Now considering replacing rear
Dunlop K555 150/80-15 Radial  to Michelin Commander II 150/90-B15 Bead
has anybody tried that and can I expect softer ride (since Venox rear is very stiff to my taste?)

Any comments on those experiments?

10
Venox 250 / Re: Do I have bad fuel economy?
« on: August 03, 2018, 10:31:55 AM »
I have worn out Venox 250 EFI made 2007.
19.000 kilometrage.
Recently used Shell Ultra 100 octane.
When low fuel light lit, waited extra 30km and filled to the max. 10,88l entered into supposedly 14l fuel tank, after driving 278km.
Much to my surprise this is 3.92l/100km or 60mpg.
Sunny weather 30+ Celsius >=86F large Polish city, flatland.
Commuting 2x6km daily in large city, every odd day 40km trip in random places around city, revving to the max after each light, but on lnger straight I like to run on reduced RPM+higher gear (for sound and economy).
Using synthetic Shell 10W40 and Liqui Moly Motorbike Oil Additive MoS2 125ml 1580.

Check tyre pressure, lubricate chain, change engine oil to something fresh then measure fuel consumption by noting on paper true fuel quantinty on gas station, then recalc using kilometrage counter. Understand that low fuel sensor is in itself inaccurate by 1-2l.

11
Venox 250 / Upper exhaust much cooler than lower one
« on: March 29, 2018, 05:11:24 PM »
Hi,
I have just bought Kymco Venox made around 2007. So far I have only 100km on it, being an owner since 8 weeks (2 rides).
Used for 11 years in northern Italy, some minor marks of sun on rear tire, scratches here or there, rusty exhaust pipe connector but works fine. This is my first motorcycle, I am 40 yrs old and have 15 years car driving experience. Bought from bike trading company in Poland. The bike runs very well and smooth for its age (has loud gear changes etc from car user perspective). Bike kilometrage is 26000.

Much to my surprise, I have found that exhaust from upper tube has much less pressure than from the lower one. Lower tube has slight discoloring (no serious discoloring on collectors) but upper tube has no discoloring and I can touch it with my hand for a split second after 40km city ride without getting burnt. It is only slightly hotter than engine body.

Does it means that:
-all Venoxes are like that?
-has anybody modified the exhaust (no signs of it)? Is it common to modify Venox exhaust like that?
-my Venox has only left saddlebag mounted. Somebody was aware the exhaust might get hot?

Is it dangerous in principle for engine lifespan? The motorcycle runs really fine, incl in very cold weather (like -10C).

I can make measurement of it but got no IR camera and weather is not yet compatible with city riding.

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