990 SD, FI indicating, won’t start

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steeeve66
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990 SD, FI indicating, won’t start

Postby steeeve66 » Sat Mar 28, 2020 10:40 am

Hi all,
Apologies if this has been covered (I did a search but couldn’t find..)
My 2007 990 SD is giving an FI warning when I switch ignition on; 3 long 3 short flashes - manual says its; Injection Cylinder 1 - circuit fault. It turns over but won’t start.

Is this likely to be a fuel injector just a bit gummed up as it’s not been used in a few months? An easy fix..? How hard is it to get to..?

Many thanks,
Steve
Superduke 990. FZS Fazer1000. CBR600FS-1. CB500F.

Someone sent me a postcard picture of the earth. On the back it said, "Wish you were here."

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No. 47
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Re: 990 SD, FI indicating, won’t start

Postby No. 47 » Sat Mar 28, 2020 12:27 pm

Injector valves are mounted on throttle body - page 7-44 of rebuild manual re electrical checks.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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steeeve66
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Re: 990 SD, FI indicating, won’t start

Postby steeeve66 » Sun Mar 29, 2020 8:29 am

No. 47 wrote:Injector valves are mounted on throttle body - page 7-44 of rebuild manual re electrical checks.


Many thanks - before I start dismantling the thing in order to get to them are there any useful tips..? I understand the tank can be a bit tricky getting back on?
Superduke 990. FZS Fazer1000. CBR600FS-1. CB500F.

Someone sent me a postcard picture of the earth. On the back it said, "Wish you were here."

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RichUK
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Re: 990 SD, FI indicating, won’t start

Postby RichUK » Sun Mar 29, 2020 9:36 am

Tank isn't too bad. I found a slim chock of wood that fits in there and gives me enough leverage to flex the tank back in and hold it there whilst I get the bolt back in.

With TuneECU you can actually test the injector operation (according to the website), but if you look on youtube there are plenty of videos of people showing how to clean injectors when off the bike.

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No. 47
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Re: 990 SD, FI indicating, won’t start

Postby No. 47 » Sun Mar 29, 2020 10:22 am

steeeve66 wrote:
No. 47 wrote:Injector valves are mounted on throttle body - page 7-44 of rebuild manual re electrical checks.


Many thanks - before I start dismantling the thing in order to get to them are there any useful tips..? I understand the tank can be a bit tricky getting back on?


Where are you in Kent?
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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steeeve66
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Re: 990 SD, FI indicating, won’t start

Postby steeeve66 » Sun Mar 29, 2020 11:04 am

No. 47 wrote:
steeeve66 wrote:
No. 47 wrote:Injector valves are mounted on throttle body - page 7-44 of rebuild manual re electrical checks.


Many thanks - before I start dismantling the thing in order to get to them are there any useful tips..? I understand the tank can be a bit tricky getting back on?


Where are you in Kent?


Im in leafy Meopham.

I looked at some useful pics on luikki’s thread showing him re-locating the battery and I reckon I should be ok so long as the tank and air box come off ok. It’s the one thing since I bought the bike back in ‘07 that I’ve not had to do.

On the plus side, I’ve not much else to do over the next few weeks, so no need to rush...
Superduke 990. FZS Fazer1000. CBR600FS-1. CB500F.

Someone sent me a postcard picture of the earth. On the back it said, "Wish you were here."

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No. 47
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Re: 990 SD, FI indicating, won’t start

Postby No. 47 » Sun Mar 29, 2020 12:56 pm

East Peckham, if you need any help.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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steeeve66
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Re: 990 SD, FI indicating, won’t start

Postby steeeve66 » Thu Jun 18, 2020 11:24 am

Update:
In case anyone is interested.. problem was solved.
The fault turned out to be damaged wires on the Big Grey Connector (BGC - located under the frame to the right of the ECG behind the steering stem). For those who don’t know; it basically connects all the fuel injector wires (15 in total) to the ECG.
It’s easy enough to get to, the biggest agg was getting the tank off or, more accurately, getting the tank back on again... :(

I was fortunate in that I found a decent condition replacement on eBay - but it doesn’t appear to be something you can buy separately from KTM so if the same should happen to your 990 you may be faced with fitting a new connector to the existing wires.
It’s something I did look into prior to finding the replacement - but it’s fiddly; most likely you’ll need to replace both sides (so 30 wires in total). I did find a supplier of ‘weatherproof’ connectors but I couldn’t get it to work; the metal inserts didn’t fit - it might be fixable, but it’s not something I pursued as I didn’t need to. Connector was from Farnell -
https://uk.farnell.com/itt-cannon/13201 ... dp/3126301

I strongly suggest checking before using them, I couldn’t see how to make it work and they didn’t respond when I contacted them after I purchased.

To sum up; I suspect if you get the same FI warning I got it’s very unlikely to be a fault with the injectors (although I cleaned them anyway) - so check all the wiring thoroughly; on the 990 much of it is oddly routed/exposed and so prone, certainly after 13 years of use, to fail..
Superduke 990. FZS Fazer1000. CBR600FS-1. CB500F.

Someone sent me a postcard picture of the earth. On the back it said, "Wish you were here."

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No. 47
Master of the twisties
 
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Re: 990 SD, FI indicating, won’t start

Postby No. 47 » Thu Jun 18, 2020 12:29 pm

Minor correction - BGC and (all?) other connectors are available from KTM - see Spare Connectors here viewtopic.php?f=18&t=16897
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S


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