I joined up on this site a number of years ago and have been able to sort all problems I've had with my bike till today :-(
Its a 2009 XT660R no mods. Purchased with 3000km and now at 25000kms. Always maintained it regular. I'm Australian from WA. I've never been able to access the diagnostics since I purchased the bike.. Error Code 4..but that's never affected anything. Bike has always run great and reliable till now..
In a Nutshell. I turn the key, no priming of my fuel pump and red temp light is displayed. Bike will turn over but wont start. Just finished pulling every connector and sprayed them all. All fuses good. If I disconnect the ECU comes up Error 1 which is expected. Could you please point me in the right direction from here. No service dealers here in Cebu so as always it's always been up to me to repair.

Appreciate anything you can help with.

Cheers
Brad

G'day mate

Sorry I'm no expert (some may be along later) so all i can suggest is, Have you tried using the RED key for a cheap and easy first try.

hope all goes well

Hi Leo, Bad news is I never got a red key when I purchased the bike. I got it second hand at 3000km.

Could be a number of things: immobiliser, fuel pump, fuel pump relay or the lean angle cut-off switch? You'll have to test each component one at a time and see if you can isolate the problem. Has the bike been on it's side? What's the immobiliser LED doing/showing? Is the engine trouble warning lamp lit or perhaps flashing when you press the starter?

More often than not the error Er-04 (ECU-dash communication) is a broken/abraded wire or a dodgy connection. There are obviously several strange things going on here. It's odd that the temperature warning light would be illuminated, unless the sensor is stuck in the closed position or there is a short in the wiring, either way that in itself shouldn't cause it to be a non-starter.

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Really starting to give me a headache now. Basically I turn the key, soon after the Temp Warning Light is Illuminated. Fuel Pump wont Prime. It's been intermittent but now it's always the case. I cant seem to pinpoint. Just wondering the best components to change out. Can I do a straight swap ECU like for like without having any issues. I'm still going thru testing of circuits.

I had/have a similar problem. In my case the fuse for FI kept blowing in the fuse box accessible under the seat if you haven't checked that. From there something else blew which is pointing towards the ECU as the fuel pump & injectors are also not getting power. So far Yamaha says the ECU, Ignition lock, keys, must all be replaced. I also don't have a red key.. Also having some things checked on the bike still, but sounds like a similar problem. I somehow believe the fault is related to the fact that the bike cuts out so frequently while driving due to the sluggish fuel delivery and all those spikes/ drops had adverse effects on the ECU.. but that's just my opinion.

I'll let you know once I know more.. Please post again once you've made a conclusion on your side..