I have identical problem as svele
I"m srtuggle more then two years now with surging and hade no ideas aboute problem white ECU
Unfortunately I was yesterday find aboute this topic
my warranty has gone :eusa_wall::eusa_wall::eusa_wall:

and I"m sorry aboute my engish

Hi All
 

I just looked up the frame number of my bike as I have had some problems with it cutting out two times and being new to a big bike it is a bit scary when the engine just stops and you roll to a stop thank god it was not on a roundabout living in Milton Keynes,:crybaby2: and I have a very juddery throttle at low speeds my frame number ends in 4938 and the ECU has 5VK-8591A-00 both sound like they are in the bad ECU bracket! The bike is going in to be look at on 4/06/08 and the warranty runs out on the 20/06/08 so some advice on this so I don’t look to stupid with the mechanic at the garage.

Unless you live in a glass house, print the attached docs and hand them to your local AUTHORIZED Yamaha dealer they should know whats what and assist you, but you must do it while still under warranty

good luck

Well got the bike back and yamaha have told the shop not to change the ECU :smilies0979: but thay did play with it a bit and it runs abit better now.

Sorry to ask a stupid question, but in the attached doc it says range
XT660R Up to frame no. DM015-007858 XT660X Up to frame no. DM014-006257

I just bought a second hand XT660X Year of reg 2006 and its chassis number
goes DM015X5A000430 but that seems to be the range for the XT660R not XT660X. So is my bike good or bad ? Without having a part number for the ECU how do I tell ? :)

Being a 06 model you should be ok, to be sure what is your ECU number? The Asia Pacific XT's show a XTR frame number on a XTX for some reason, no one can tell me why.

5VK-8591A-01 so ok on that thanks :)

That's the good one, they are like gold very hard to find.:clock:

Kev Im a bit confused about JCM's Throttle Sensor Adjustment instructions.
He states before you start "It should be between 16 - 18." Then he goes on to say "Set the value to between 15 & 18." and you say you have found in playing around 16 is good. Mine is set to 16, so that would suggest its as good as it can be ? Any thoughts.

Basically the engine ECU needs a certain voltage range to know where the throttle is & between 16 & 18 it knows it is at idle. I find my best running postion is 16 for my bike.

One can set the TPS out of theses ranges & it effects the running of the bike. The higher the TPS reading lets say 23 the bike will produce more power but surges more on the cruise, at 14 the bike has less surge while cruising but does cut out at times.

Thanks Kev FYI
I have a -01 ECU and a TPS starting with 46, the local Yamaha dealer showed me the recall form for the TPS and it had a list of PN's, starting with 45, 46, 47... etc. Some where "good / new " some "bad / old ". Unfortunately I did not write down the list, but I can tell you 46... was a "good" one, 45 and 47 bad. Even with that checked I am still getting a very jurky throtle at low revs. I have adjusted the CO levels and that has make some improvments. I told the dealer I was going to try out your Fuel injection mod, but he said hold off until he had talked to Yamaha. Because he had been riding the xt660 2007 and that was not smooth either ( OS sensor type ). I will tell you if I get joy :)

Hi Kev,

I have an Oct 2007 XTR and it also seems to suffer from a severe case of surging ( fortunately no cutting out). I've read most of the threads above and realized that there is not a lot of information available for the later models. Do you have any new ideas for surging in these models yet?

I've just done a trip to Cape Town with the bike and man, I don't want to sell it because of this slight irritating glitch. Changes to CO1 settings didn't offer any real improvements.

If your 07 XTR is fitted with a Lambda probe or O2 sensor, this will be difficult to cure, however if it doesn't have that sensor then you can safely fit a Kev Mod and experience a surge free bike, in which case please PM Kev for prices and availabilty.
Thanks

I have been working on a solution for the 07/08 XT's for a year now & keep finding hurdles when I think I am close. We are testing a few different ideas around the world at the moment. So hopefully we will find a solution soon.

I just want to check are you saying if your bike was bought second hand and has no warranty, that my yamaha dealer , still has to replace the ECU even though i bought the bike privately. Mine has the old ECU in it and it fluffs out at low revs if you dropping down gears at a junction etc.

The ECU is changed for surging problems, the TPS is changed for stalling when slowing down pulling the clutch in & blipping the throttle.

Once a bike is out of warranty Yamaha are not obligated to replace any part, they will how ever look at cases out of warranty at their discretion.

If you don't have any luck with the dealer, send off an E-mail to Yamaha asking for assistance & describe the fault, do not diagnose it for them saying you want a ECU or TPS they don't like that.

As I said in one of your previous post today, if you don't come right come back to me.

Good luck.

I don't quite get it with the chassi number range. Can you guys help me?
My chassi number is VG5DM011-000007626 does this fall in the "bad" range? :team[1]:

DM011 as far as I am aware is a 2004MY VIN (XTR?)

I'd say a DM011 VIN would fall into the above catagory as it is most certainly before (or up to) the two VIN numbers listed above.

Safest bet would be to check the part number on the ECU to see if it one of the "bad" ones. It may well have already been changed for the updated ECU by Yamaha earlier in the bike's life?

Yea it's a XTR. The thing is that I'am thinking of buying this bike. I've asked the owner to check the part number on the ECU but he could'nt figure it out. He said it was 5VK-090, and then he could'nt se anymore. He is the 7:th owner of the bike and doesn't know much about its history.

He's only found part of the ECU code. He obviously couldn't see the end of it (which is the important bit). Ask him to look again!

Just seen this thread, and having now read it i can understand what happened to me the other day wasnt my fault at all.

Having just bought my 2004 bike, and done less than ten miles on it, i set off from some lights and the bike just cut out on me. I had to pull in to the side of the road and wave the cars past that i had just filtered past :angry7:

I was mystified at the time. Not so now. Have to say though it doesnt surge at all.

So i have just verified my frame number and ECU number and they both point to the ECU been "faulty" - what are my next steps? The bike is now 9 years old - are Yamaha UK still up for changing ECU's at this age? Obviously a safety issue with the bike just cutting out which i'd like to cure asap :confused2:


Edited to say - just realised the bike also has a number "31" TPS still fitted which apparently can cause cutting out!


If the dealer route is a no-go, are there any "work arounds" i can do to help minimise the cutting out?

Cheers :)

Rich W, I would think there is a good chance Yamaha would update your ECU.
Why don't you ask them?

Hi Harry,

I have just spoken to Yamaha UK who have said there is only one recall on the bike and that is for the TPS. I will get the TPS changed and see where we go from there, the bike rides fine without surging, and so if i can cure this cutting out i will be happy (though to be fair it's only cut out once anyway).


:)

Let us know how you get on.

Can you have a good look at your TPS & give us the latest number off it?

Hi Kev, the number on the TPS is 313715 - the letters are faded but the first two are definitely 31 and from what i can gather that is the old faulty TPS.

The bike is going in tomorrow for the dealer to look at it; I spoke to Yamaha GB today who have said that the bike has already had the TPS changed, though by their own admission it wouldnt be the first they've come across where their records have been wrong. If it is an old faulty one they will replace it regardless.

Sorry I was not clear enough I was after the numbers on the new TPS.

Hi folks,

Well, this thread makes very interesting reading! I bought my 2005/6 XTX nearly 3 years ago, after having done some research into the bike. I had read that it suffers from surging, but I decided I'd see how it goes and would probably be able to ride around the issue. Sure enough, for the most part I can ride around the surging, though it's not ideal.

Of greater concern is the issue that it cuts out / stalls quite often, mostly when changing down gears. Thankfully it hasn't resulted in an accident (yet!) as I've been able to pull and hold the clutch in while restarting the bike. To be honest, I had wondered if it was something I was doing wrong, until this week when someone said there had been a recall on these bikes years ago. I wasn't aware of the recall when I was buying the bike, so I've been doing some reading and checking...

My frame number ends in 9112, so it's well outside the supposedly dodgy range, but it has the older -00 ECU:
http://i163.photobucket.com/albums/t...ps16566776.jpg

It doesn't seem to be one of the -00s with the white dot on the back:
http://i163.photobucket.com/albums/t...ps93efd132.jpg

I can't understand how this could have happened, if all bikes after 6257 should have had the -01 ECU.

I called the Yamaha dealer who sold me the bike and their records show that the TPS was replaced via the recall in November 2006. If I have understood correctly, this recall was supposed to have fixed the cutting out / stalling. But it clearly hasn't. The part number on the TPS a bit faded but I think starts with 46:
http://i163.photobucket.com/albums/t...psc765a12f.jpg

I took it off and can see clearly that it's the A1 version:
http://i163.photobucket.com/albums/t...ps88a3770d.jpg

So I'm left with a couple of questions...

Yamaha UK seem to be satisfied that the TPS has already been replaced (I'm not disputing that it was) so am I likely to be able to persuade them to replace it again, to the A2 version? I realise they've already changed the part, but it's no good if the new part doesn't fix the issue it was supposed to! The chap I spoke to at Yamaha UK wasn't familiar with the A1 and A2 versions.

Having spoken to the dealer who originally sold the bike from new, plus the dealer who sold me the bike, and also Yamaha UK, no-one can understand how my bike has the older ECU. With it being well outside the warranty period is there any chance I'll be able to persuade anyone to foot the bill for a replacement, on the basis that it should have had the newer one all along?

Finally, if I do get a replacement ECU will I also have to replace the ignition / immobiliser system?

Apologies for the long post, but I hope some of you very knowledgeable folks on here might be able to help!

Stuart

Odd about the frame number and ECU match?:eusa_think:

It is a relatively old bike though, so you (or Yamaha/the dealers) can never be 100% sure what's happened to it, or been fiddled with/changed over the years?

You've got nothing to lose in trying? If you don't ask the question you'll never know the answer!

Registering the keys/immobiliser to a new ECU is a straight forward job and only takes a few minutes, so no worries with that one.

Hello
 

Mine is below on both lots, do you have to pay for the replacement or is it covered? Or do you need warrenty etc, thanks!

It is a long time out of warranty, I do not like your chances.

I'm not sure what the issues are with the faulty ECU's but is the engine cutting off when downshifting sometimes one of them?

I have a 2004 xtr, which has surging issues also but mainly the engine cuts out at the worst times (always when downshifting). The surging doesn't phase me, I accept it for what it is.

Just had a new battery installed last week that didn't fix the problem.

How much would it cost me to fix this issue? Cheers.

Cutting out when downshifting can more often than not can be attributed to a low tick-over or idle speed. Make sure your idle is set to around the 1450-1500rpm mark on a warm engine.

If you want to get the rev counter to display in the dash, follow this link:

http://www.xt660.com/showpost.php?p=4194&postcount=4

If you haven�t already read this thread, it pretty much covers everything you can do to minimise surging, cutting out and general rough running:

http://www.xt660.com/showthread.php?t=23042

I am maybe a little bit late, but the links you provide for the photos dont work for me, they just show the profile. Can you send them to me maybe? I'm trying to fix my XT660R's cut outs ...

They might not work because the host of those photos has removed the links, we don't host any links posted by the forum users.