I have a 2004 Sprint 955i RS with the single swing arm set up. From what I understand and someone can correct me if I am wrong, that the single swing arm RS was introduced late and one of the last RS sold. Anyway, I have owned my RS for the last 5 years and has been a fun reliable bike until the last couple weeks where I have faced a few problems. I was riding home the other week and the instrument display including the tack just blinked on and off and then went out. After investigation I found a wire off the connection that is under the tank right next to the connection for the fan that had a wire that was rubbing against the frame and was only connected by a few wires. I used a butt connector and heat shrink to fix that and retapped up the wiring harness. Then I tie strapped the cable to the wiring hardness to keep it way from the frame. I hooked the bike up to my computer and cleared the code and everything appeared to ok. I took it for a short ride and it ran great! Sunday I broke down on a ride. The display just went blank and about a quarter mile later the bike just quit. I tried to start it but there was nothing. After about a 45 minutes (waiting for help) the bike turned over a couple of time but the battery did not hav the charge to start it. I then jumped the bike and it started but quit only a few yards later. Loaded on a truck and brought it home. When I hooked up the OBDII, I got 8 error codes: P0351, 52, 53 and P1351, 52, 53 and P0230, p1231. Checking the ignition coils the shop manual states that the coils should read 8 ohms. I got 1.2 ohms from the ECU terminal to the Main power relay. I then took the tank off and read each coil individually and got the same 1.2 ohms. No, faults to ground were found. I find it hard to believe that all the coils would go out and that they would all read the same. Can this happen? That is all the coils going out at the same time? I checked the fuel pump circuit and could not find a fault either. Then I found the 30 amp main fuse was melted, yes melted. After I put everything back together and changed the fuse. I put the battery on a battery tender (it read 11.5 VDC). With the computer hooked up, I cleared the codes and tested the fuel pump, no fault was annotated. I then jumped the bike again and it started right up but in a few minutes the main fuse was starting to get hot again. I stopped the bike. Anyone have anything similar happen or anyone have info as where then think I should go from here. Any help will be appreciated!!! R/Paul
Hi and welcome, Just a thought about the 30A fuse; you said it was melted do you mean the plastic casing of the fuse? If so the it will probably do it again as you probably have a high resistance connection in the fuse holder. You should replace that or bypass it. That could be a cause of the other issues or a symptom of reg/rec issues!!
Yes, the plastic melted but the fuse just had the smallest of gaps in it. There was not since of the fuse element blowing like you would normally see. Very strange! Bypassing it,,,, just not going to do that. There has got to be something. If the coils are indeed bad at 1.2 ohms as the manual suggests it would result in higher amperage across that circuit and should have blown the fuse. If one of the 3 coils went bad or maybe even two, but all three? And basically all at the same time. I’m having a hard time with that but I cannot find any specs on the coils. They made at least 2 different coils for this bike over the years and mine is a little odd because it was the last year of production (mine being a later model) and they used some of the ST’s part on the RS. Thanks and Yup! The plastic was melted. I reposted this problem on the tech page. I think I will have to remove the fuse box and check the wires under it to see if there are any issues there. A set of new ignition coils are not cheap and will not put them in until I know what to root cause is. I am leaning toward the alternator/rectifier problem. We will see.
Thank you for the warm welcome. I have gotten some valuable info and instruction already and can’t wait to get out and go to work to get my RS back on the road!
I think I have it corrected thanks to the forum and a special thanks to D’Ecosse! I nicked the O-ring on one of the fuel quick disconnect fittings and had to stop. I got one today and won’t be able to replace it and put the bike back together until Friday. Life is just too busy but, if all works well, I will be able to get a ride in this weekend. Again, Thanks for the welcome and Thanks for all the Help! R/Paul