Gen 1 Error Codes 33, 34, 35, 36

[massmike]

Passing along this in case anyone else is trying to diagnose a possible cause of these error codes. My Gen 1 S10 would trip these error codes intermittently. Causing the engine to run on one cylinder. It would run fine for several hundred miles then misfire. After consulting the factory service manual and doing the diagnosis procedure I could not find the issue. After months of trial and error I found the cause. Every one of the modular waterproof connectors from the wiring harness to the coil packs / Plug caps had lost their spring tension on the spade connectors. The modular connector snapped on positively and each one tested ok for continuity. Only open pulling the actual spade connector out of the waterproof connector and trying it directly on the male spade to the coil/Plug cap did I discover it had a loose fit with no tension to grip the male spade. Vibration would cause a poor connection and fault code in the bikes icu. The fix was to purchase a used wiring harness with good connectors and splice then onto my bikes harness. Hopefully this might help anyone out there who's got one of those error codes above and is having trouble diagnosing the cause.

 

[PineLaneRider]

Generic question. Do the codes set off a light on the dash? I have experienced what seemed like a dropped cylinder twice iin my 20k miles. I attributed it to water in the gas or possibly water in the plug well because the last time it happened was after a torrential downpour. It lasted though about half a tank of gas.

 

[massmike]

Generic question. Do the codes set off a light on the dash? I have experienced what seemed like a dropped cylinder twice iin my 20k miles. I attributed it to water in the gas or possibly water in the plug well because the last time it happened was after a torrential downpour. It lasted though about half a tank of gas.

On the Gen 1 bikes there is a procedure to retrieve any falt codes via your speedo buttons. ( hold down both buttons while turning on the ignition keyy. Continue to hold for eight seconds and the computer will go into diagnostic mode. By scrolling through the different sensor checks you will come to history. Thus is where the error codes are stored. It is also possible to erase error codes after you address the problem. ) If you consult the service manual or online sources you can determine what codes are for which issues. There is a table showing cause and solution for the error codes. However in my case it was an intermittent problem that would test fine until the next occurrence. My bike has 30k miles and why the coil pack/Plug can connectors lost tension is a mystery. I only change the plugs every other year so over use dosent seem likely. I'm guessing it was a quality control issue and the heat treating wasn't correct. With time, heat and vibration they loosen. The waterproof modular connector makes it feel as if it was a solid connection. Not until removing the female connector from the plug did I find the cause. If your having an intermittent issue it might be the cause. Check your icu faunt code history and see if any codes exist. They don't automatically erase even if it goes back to running correctly.

 

[massmike]

In the five months since I fixed this issue with used connectors from a Salvage wiring harness I have found that new connectors are available. However I do have a word of caution to pass along. While researching these I kept being told that they were special and no source existed. Every electrical connector supplier I contacted said that those are made specifically for the OEM manufacturer. That just didn't seem logical to me. I finally contacted an automotive connector specialist that specializes in rare and hard to find connectors who identified the connectors and had them available. They wanted $70 each for just one modular connector or $4 each for one internal metal connector without the modular connector or moisture seal. This seemed outrageous to me. After weeks of more internet searches, I FINALLY found what I new must be out there somewhere. They are called Denso Coil connector kits. They are sold in the USA for $6 and come with the modular connector, Internal metal connectors (and extra one incase you mess up installation) as well as weather proof seals. They are used an numerous motorcycles and some automotive applications.

 

[audiowize]

http://www.cycleterminal.com/cop-connectors.html

If this guy doesn't have it, I never hesitate to bug him with pictures in an e-mail to ask if he can identify stuff.