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I haven't been active on BARF in years, partly because I haven't been riding. I cracked the frame in an accident and had GP Frame and Wheel weld it up. After a year or two of use, the crack reopened. I decided to drop the motor, swap the frame, and reassemble the bike, but now it won't start. There's a short or something somewhere in the wiring harness, and I can't figure out where.
I'm looking for someone familiar with the bike—it's a 2007 Aprilia Tuono 1000R, though the wiring should be similar to any Rotax-powered Aprilia from that era. My garage is set up like a workstation at MotoGuild, so all the tools you might need are here. I've replaced nearly every part except the ECU, which might be next if something is shorted out. I just need someone to verify that everything's been done correctly.
Speaking of MotoGuild I've reached out to them, but no mechanics are interested in the project. Several shops have also declined as well, since I dropped the motor and replaced the frame—they don't want to fix another "mechanic's" mistakes.
Here's what's happening now:
I'm looking for someone familiar with the bike—it's a 2007 Aprilia Tuono 1000R, though the wiring should be similar to any Rotax-powered Aprilia from that era. My garage is set up like a workstation at MotoGuild, so all the tools you might need are here. I've replaced nearly every part except the ECU, which might be next if something is shorted out. I just need someone to verify that everything's been done correctly.
Speaking of MotoGuild I've reached out to them, but no mechanics are interested in the project. Several shops have also declined as well, since I dropped the motor and replaced the frame—they don't want to fix another "mechanic's" mistakes.
Here's what's happening now:
- Current Symptoms:
- Insert key, turn it on: Dashboard animation starts, fuel pump primes, and fuel is pumped into the combustion chambers.
- Dashboard shows error codes P-1611 and A-44, indicating an "idle control stepper motor error." I replaced the stepper motor and cleared the ECU codes, but the error persists. These codes shouldn't prevent the bike from starting but could have the same cause, be it related to wiring, or the ECU being fried.
- Occasionally, the starter motor turns when the button is pressed, but it's rare. Most of the time, pressing the starter just runs the fuel pump, dumps fuel into the combustion chamber, and restarts the dash display.
- Things I've Checked:
- Sensor connections and completeness of the wiring harness. Every plug on the bike is a different shape so one can't plug something into the wrong socket, but had to make sure everything was plugged in.
- Manually completed the circuit on the starter solenoid to ensure the starter motor turns.
- Threw parts at it: starter solenoid, MAF sensor, idle stepper motor, fuses, and battery—no difference.
- Things I Haven't Done:
- The ground wires to the motor are hard to check, tightly jammed between the motor, frame and bulk of the wire harness. Checking them might require dropping the frame or disassembling the wiring harness.
- Tried a new ECU to see if it resolves the issue. I'm weary of spending $150 on a part I might also fry if it's both a faulty ECU and a wiring issue.
- Other Potential Issues:
- The vacuum lines were modified by the previous owner to delete the EVAP canister. I'm not sure I ran them correctly. While this shouldn't stop the bike from turning over, it might prevent it from starting in the future. Aprilia's diagrams are incorrect, which doesn't help.