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Discussion Starter #1
Hi all,

I stupidly lost all of my bike keys (AU model with an immobiliser), so my only option according to Suzuki was to replace the ECU and all key barrels. I ended up calling a locksmith who was able to cut new keys and get the code from the ECU at a much cheaper price. The bike was running perfectly before this, but unfortunately it won't run at all now. It's a 2014 model, with less than 10,000Ks on the clock and had never missed a beat. Here is a timeline of events/symptoms:

1. While the locksmith was there cutting the new keys the bike started fine and seemed to run (well idle anyway) normally.

2. About an hour later I went to ride the bike home it was a bit hesitant when starting and idled pretty rough. After it warmed up, it seemed to go ok and I managed to ride it home (a 15min ride). It seemed a little off, but not too bad.

3. Two days later, I went to start the bike and it was really hesitant again and really rough idle once started (almost like running on 3 cylinders). I stopped the engine and since then I've not been able to start it back up again at all. It turns over and cranks fine, but won't start.


Troubleshooting:

- Spark:

Getting spark on all plugs while cranking.

-Fuel:

Assuming it was a fuel starvation issue, I've pulled the fuel pump out and given it a complete clean and replaced the filter/strainer pad and o-rings. The fuel pump is definitely priming before when ignitions is on. Fuel pressure also seems fine, if I pull the line off the fuel rail to the injectors, it sprays out.
The plugs were fairly dry though.. so it seems like the injectors are not firing. I guess I could try pouring fuel directly into the chambers and see if it fires up for a little while.
I did fill the bike up with fuel from a different place to my usual around 2 days before all of this. It seems unlikely but possibly it's a really bad batch of fuel.. I may try draining it and filling with new stuff.

- ECU:

There are no error codes. If I put it in dealer mode it just shows -C00.
It turns out the ECU had to be cut open in order to get the immobiliser key code. It was a readonly operation, nothing written back - but could this have caused any issues? Unfortunately I don't have access to another ECU to test.


If you've read up to here, thanks!
Does anyone have ideas or suggestions on what to check for next before having to take into a dealer/mechanic?
Has anyone heard of this happening after getting the key code read from the ECU?
 

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I take it you don't get a flashing FI on the dash? What does "cut open" entail exactly? Can you post a photo? Given that this happened after cutting new keys and assuming that the only part of the bike that was tampered was the ECU, I'd say it's more than likely that the problem lies there an not with the pump or other subsystems. Perhaps the electrical connection was compromised, for instance if oil or dirt was allowed into the couplers, or the ECU was not resealed appropriately and water or other contaminants made their way inside (which would explain the gradual failure), or perhaps cutting it open damaged it somehow.
 

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Discussion Starter #3
Yep no FI light is on or flashing.

I'll try and get a photo of the ECU up in a bit. Essentially it's a small square cut in one of the corners to get access to one of the microchips. The hole does appear to be covered pretty well, so I don't expect there was any contaminants were getting in. The bike has been stored under cover in a garage since then.

The reason for suspecting fuel filter/pump issues was due to the tank being lifted to get access to the ECU. Potentially sediment in the tank got disturbed and clogged the filter. Given the gradual failure, it did seem like it could make sense.

I'm was hoping it could have been coincidental and that something else got disturbed which was about to fail soon anyway, but it does seems like the ECU is the culprit. I was hoping to try and rule out anything else first as I don't have access to another ECU to test.
 

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Discussion Starter #4
So.. it's running again!

Turns out I must have picked up a batch of the worst fuel available.. It must have been completely coincidental that the new keys were created at the same time.

As mentioned in my first post, I had filled up a few days prior from a different place, so as a last ditch attempt I decided to flush out all of that fuel and try some new stuff from my usual place - it fired straight up and seems to be running normal again.


Anyone heard of fuel so bad that the bike can't even start? I'm wondering if this place is selling 91 octane as 98.. but surely the bike would still run on 91, just badly?
 
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