V boost set up / issue

[christopher509]

Hello everybody. Some information would be appreciated.
I am rebuilding a max from boxes of bits and have got to the point of installing the v boost system. The system was working ok when removed about 2 years ago and dry stored until now.
I tested the system by turning on the ignition and the systems starts to operate but does not open fully or return to the closed position. I can twist the motor a little to full open and it will then close.
If I remove the cable from the motor and operate it, then the motor opens and closes as normal but with the cable reconnected it repeats the not fully open routine.
The butterflies open fully and feel free to move. Battery shows 12.7 volts.
I have checked the clearances as per the manual and all seems within tolerance and have even tried a different motor but the same thig happens. The cable moves freely when disconnected from the motor
Any ideas on what to do next would be gratefully received.

Regards Chris.

 

[one2dmax]

Flex the box itself. It's common for them to develop micro cracks which cause intermittent operation. Flexing the box can reestablish the connection temporarily (while being flexed). If that makes it work then you need to get the board out of the housing and remelt the connections (especially around where the wires are soldered coming into the board).

 

[christopher509]

Flex the box itself. It's common for them to develop micro cracks which cause intermittent operation. Flexing the box can reestablish the connection temporarily (while being flexed). If that makes it work then you need to get the board out of the housing and remelt the connections (especially around where the wires are soldered coming into the board).

Thanks for the advice Sean, I will check it out and let you know how I get on .

Regards Chris.

 

[christopher509]

Thanks for the advice Sean, I will check it out and let you know how I get on .

Regards Chris.

Hello, just a quick update.
Plugged the vboost system into a known good running bike loom and all works well so Seans tip about the control box looks to be right.
Now to open it up and see what can be done.

Regards Chris.

 

[brian hicks]

Hello, just a quick update.
Plugged the vboost system into a known good running bike loom and all works well so Seans tip about the control box looks to be right.
Now to open it up and see what can be done.

Regards Chris.

You will need solder flux paste, a good soldering iron and a magnifying glass. If you are not experienced at soldering then get someone to do it for you.

 

[christopher509]

Thanks for that , I have opened it up and it appears to be covered in some sort of gel so not sure if that is standard or has been repaired in the past?

Regards Chris.

 

[christopher509]

Another update and question. Investigations /work done so far.
I have tested the original vboost ecu and a spare I have on a running bike, a number of times, and both operate as they should.
Tested the motor and a spare on the good bike and all works as it should.
Removed the inlet manifold and tested the complete system on the other bike and it all works as it should.
Obtained a complete system which tested out fine on the running bike but when fitted to the rebuild bike it does the same thing in that when the ignition is turned on the motor opens the butterflies but does not go to full rotation and reset. It stops about 1/4 inch from full rotation so when I rotate it fully by hand it then closes the butterflies.
I notice when testing on the other bike it would fully open and close then open slightly taking up the slack in the cable as does the running bikes own system.
It does not do this on the rebuild bike when I fully open it, it just closes.

So, the question now is .....am I missing /doing something wrong? Is there anything else electrically that could cause this or could it be a main ecu or loom fault. I tested the main ECU on the good bike, and it worked ok.
Any thoughts or ideas will be gratefully received as I have run out of ideas

Regards Chris.

Thanks for that , I have opened it up and it appears to be covered in some sort of gel so not sure if that is standard or has been repaired in the past?

Regards Chris.

 

[MaxMidnight]

You say you have checked the clearances i.e. the control cable and V Boost synchronisation?
(Section 5-13 to 15 refers)

 

[christopher509]

You say you have checked the clearances i.e. the control cable and V Boost synchronisation?
(Section 5-13 to 15 refers)

Hello MM , yes I have checked them following the guide in the workshop manual.

Thinking that it may be a loom issue, so I plugged everything in except the lighting / indicators and the oil level switch is permanently on. Removed it and tested that as well and the readings are as described in the manual, but the lamp stays lit regardless of the oil level.

Curiouser and curiouser ??

 

[MaxMidnight]

If it is a loom or connection issue then these are the wires you need to check.