DCT Failure?

13712km and my bike goes into limp mode.

History:
Have had one or two glitches in the time I have owned this bike.....some surprises but generally all has been OK. Heard of the possibility of getting the new maps on my ECM so I took it out, sent it to the UK and had the new maps installed. That was about 500km ago.

Rode out this morning. A short trip of about 10 km to our Rider Training facility and parked the bike. 5 hours later, start her up, select "D" and ride off. notice that the bike is not changing gears!!!! Looked down and saw a flashing "-" where the gear indicator should be. Alarmed, i came to a stop at the earliest possible time. Heard the gears clank but the flashing "-" continued. Strange. Cycled the ignition and all appeared to be back to normal. So engage "D" and ride off again......no joy. As soon as I go over 10km/hr, bike goes into the limp mode again. Come to a stop, hear the clanking again and I realize the bike has selected 2nd gear. And this is the gear that takes you home. Limped back home and pulled out my manual!

Got the DTC fault codes, Faults in the ABS system (front wheel speed sensor related), Faults in the EFI system (Front Wheel Speed Sensor related) and faults in the DCT.

Cleaned both wheel speed sensors and cleared all the faults. DCT faults came back and bike still goes to limp mode every time i go above 10km/hr.

Service manual has the fault down to "Inner mainshaft / contershaft speed ratio failure".

I am tired!!! :sad: I didnt get a bike so as to have to fix it!!!!

But what to do...

There are 4 reasons for this fault

1. Rear Wheel Speed Sensor Malfunction. Took out the sensor and cleaner it out. Checked the sensor as described in the service manual.....It is OK

go to 2

2. ABS Modulator or its circuit malfuncton. Ran the check on this and all came back OK

go to 3

3. Inner mainshaft sensor or its circuit malfunction. Have run out of time....will start this on Monday and see what happens.

By the way, reason 4 is faulty ECU :sad:

Has anyone had the DCT throw a fault??

Can't help you other than wish you luck................

And check with whoever did your ECU...

When numerous faults happen simultaneously with no other obvious cause, this usually is symptomatic of a fault which affects things globally (i.e. all the systems) such as a power supply failure, poor or improper connections, water intrusion, etc. Since you recently changed the ECU by removing and reinstalling it, this seems to be the first thing to suspect. Perhaps one of the connectors is loose, or water has shorted some pins. I'd suggest removing the ECU, carefully inspect the pins for damage such as bending. Before reinstalling, spray all the contacts of both the module and harness with contact cleaner.

Solomoto has a good suggestion.
While I know nothing about your specific problem, over the years I have found the best place to start troubleshooting is the last thing I worked on.

The inner mainshaft sensor is caushing the troubles. Chech wiring to this sensor. Maybe de connector to the ECU is not complete on its place ?

The Auto uses that front wheel sensor so if I was attacking this problem I would start with the ABS and wheel sensors. Its one of the reasons nobody can put up the DCT on the dyno's. That is based of of what I read.

Hmm the fact they are checking out good is odd.

OK guys!!! The jury is in.....Verdict?...."Faulty inner mainshaft sensor" Knowing the problem is 90% the solution!!! :rolleyes:

The service manual gives a very detailed blow by blow procedure on how to track the culprit. And following its instructions, the conclusion is this sensor. There is also a check for the wiring, which turns out to be OK.

Now the wait while I order the sensor from the UK. :rolleyes:

Question for Dutchgixxer though......how did you guess this? Has this problem occurred before? Perhaps these sensors have a "short service life"? I took the sensor out this morning to see if there is some physical damage. It looked OK with not even a scratch. However, it was a surprise to notice there were absolutely no markings on the sensor......no part number, no Honda logo, absolutely nothing!!! Makes me wonder how Mr. Honda sourced these sensors. Oh well, when the spare arrives, I will see.

Thank you all!!!

[image: View Post]fotodadi, on 05 December 2011 - 03:23 AM, said:

OK guys!!! The jury is in.....Verdict?...."Faulty inner mainshaft sensor" Knowing the problem is 90% the solution!!! :rolleyes:

The service manual gives a very detailed blow by blow procedure on how to track the culprit. And following its instructions, the conclusion is this sensor. There is also a check for the wiring, which turns out to be OK.

Now the wait while I order the sensor from the UK. :rolleyes:

Question for Dutchgixxer though......how did you guess this? Has this problem occurred before? Perhaps these sensors have a "short service life"? I took the sensor out this morning to see if there is some physical damage. It looked OK with not even a scratch. However, it was a surprise to notice there were absolutely no markings on the sensor......no part number, no Honda logo, absolutely nothing!!! Makes me wonder how Mr. Honda sourced these sensors. Oh well, when the spare arrives, I will see.

Thank you all!!!

I did check the the honda manual. ABS and wheel sensors related faults do not bring the bike in limp mode. Just a flashing light will tell you if there is a ABS mall function. The inner mainshaft sensor will bring your bike in limb mode as you already experienced. I have made a phone call to a big honda dealer in holland and they confirmed my analyse. Its a "common" problem in the DCT version. You are not the first with this error. Hopefully you fix the problem with a new inner mainshaft sensor. Tell us if the problem is solved . :tour:

[image: View Post]Dutchgixxer, on 05 December 2011 - 05:16 AM, said:

I have made a phone call to a big honda dealer in holland and they confirmed my analyse.
:huh:

[image: View Post]Dutchgixxer, on 05 December 2011 - 05:16 AM, said:

Its a "common" problem in the DCT version. You are not the first with this error.
:sad:

[image: View Post]Dutchgixxer, on 05 December 2011 - 05:16 AM, said:

Hopefully you fix the problem with a new inner mainshaft sensor. Tell us if the problem is solved :ohmy:

Thanks so much for yours!!! I certainly feels better to know its "common" This is like they say; "good news and bad news"

Just spoke to the UK dealer I bought my bike from.....replacement part cost about 140 GBP!!! :ohmy: and in the US, same part costs $77 from Ron Ayers. I have asked for a new sensor under warranty so we will see how it goes. But quick one Dutchgixxer, this being a "common" problem, could you give me some indication of just how common? I mean, its hell getting parts in Nigeria so If I need to order more sensors perhaps you could point me in the right direction. There is also another speed sensor close to this....what would you suggest.

The dealer has sold 16 DCT VFRs. 3 came back with a innershaft sensor/sensor conector problem. Al fixed under warrenty. Did you already check the wiring to the sensor ? Was the connection still water tight ?

[image: View Post]Dutchgixxer, on 05 December 2011 - 11:32 AM, said:

The dealer has sold 16 DCT VFRs. 3 came back with a innershaft sensor/sensor conector problem. Al fixed under warrenty. Did you already check the wiring to the sensor ? Was the connection still water tight ?

That's almost 20% failure rate......That cant be good!!! :ohmy: Did he give any correlation to mileage or duration of ownership? Mine has failed after about 15months and 13k+ km.

Well, I did check all the connectors and they were still water tight. I will see what will happen tomorrow with my UK dealer.