[normthenomad]

Is it possible the Power Commander is faulty? A friend with an 09 Kingpin had poor running issues and stalling. Maybe not exactly the same symptoms you’re having but he took it to The Vic Shop and Rylan said the Power Commander failed and that it’s been known to happen. He went with the Maximus tune and that’s what solved his issues. I don’t think the Maximus tune is an option for an ‘06 model and buying a new Power Commander and a dyno tune isn’t exactly a cheap option for just a guess. I don’t know how you even troubleshoot the power commander but if it’s no longer working correctly that could prevent everything else you’ve done from working. Just throwing it out there. We’re all hoping you get it sorted out.

Maximus is for the '08 and later closed loop system.
Unfortunately.

 

[Obi Steve]

Maximus is for the '08 and later closed loop system.
Unfortunately.

Have you tried letting the motor stagger along for a few minutes when it's mucking up at idle and then killing it and doing a plug reading? That might tell you if it's misfiring because of being too lean or too rich, which in turn could indicate whether you're looking at higher or lower resistance in the cable run sending the throttle point information to the ECU. TPS resistance decreases as the throttle opens. If it's too lean at idle it would mean too much resistance in that cable run, so too low a voltage input to the ECU causing too little fuel to be injected. so suggests loose connection or a frayed point in that wire.
Make sense?

 

[Motorbikerx]

Is it possible the Power Commander is faulty? A friend with an 09 Kingpin had poor running issues and stalling. Maybe not exactly the same symptoms you’re having but he took it to The Vic Shop and Rylan said the Power Commander failed and that it’s been known to happen. He went with the Maximus tune and that’s what solved his issues. I don’t think the Maximus tune is an option for an ‘06 model and buying a new Power Commander and a dyno tune isn’t exactly a cheap option for just a guess. I don’t know how you even troubleshoot the power commander but if it’s no longer working correctly that could prevent everything else you’ve done from working. Just throwing it out there. We’re all hoping you get it sorted out.

Thanks for your well wishes but right now it's looking like a short in the system.
Now I'm no electrical genius by any stretch of the imagination, but I do have the help of numerous YouTube videos on searching for a short, If I can absorb some of that knowledge, as well as use my vision(great name for a bike hey!) to locate the crux of the problem.
Got a message tonight from the bloke who bought my Vegas off me, well must be coming up two years ago.
It's been sitting in his garage unused for all that time.
He's giving me first dibs on it before listing it for sale.
Now it's got over 170,000kms on it, with almost all those kms being mine, and the engine been treated to an overbore to 109cubes and .495 cams,
All tuned and dialled in by me.....
So that's just gotta be tempting me right now..
Just thinking aloud now

 

[Motorbikerx]

Have you tried letting the motor stagger along for a few minutes when it's mucking up at idle and then killing it and doing a plug reading? That might tell you if it's misfiring because of being too lean or too rich, which in turn could indicate whether you're looking at higher or lower resistance in the cable run sending the throttle point information to the ECU. TPS resistance decreases as the throttle opens. If it's too lean at idle it would mean too much resistance in that cable run, so too low a voltage input to the ECU causing too little fuel to be injected. so suggests loose connection or a frayed point in that wire.
Make sense?

Well to be completely honest only the last two lines make any sense to me mate.
If I can't find it by Tuesday arvo, and I'm just getting home in the Benz at 1.17am from a full on 6 hours of psychedelic rock music from a couple of my favourite bands, Rinser, and Emu, check out Emu man,they're from up your way, Henry, the drummer from Zong also plays drums with Emu and the singer just slays it on heavy blues lead,
I got some vid footage from down in the moshpit for ASTRODEATH,

Still got it ringing in my ears!
Then they did Black Sabbath "Children of the Grave!"....the mosh was going off! You woulda been proud of me!

Now Sunday so this arvo Rose Tattoo ⚡are playing at Wallabys Pub in Mudgeeraba and I have a ticket👍🇦🇺....
So being realistic I won't get a look at the wires till Monday.
Now if I ain't got it pegged by Tuesday arvo there's a German bloke I know from my old drinking days(daze) who coincidentally rides a wicked chopped knucklehead, he's an electrical whiz with old stuff.
He's never had nothing to do with Victorys, or fuel injection, or ECU/ECM ,
But as said to him when I rang him and dredged him up from my dark past.
It's only wires!
We looking for a short!
Maybe you might like to ride on down too if you're free.
I'll give you a call tomorrow when I wake up.
This bloody old Benz is a joy to drive hey, I love it!
Must be getting old........

 

[Obi Steve]

Mate I'm no expert, that's for sure. Just I would expect a short to be throwing a breaker or blowing a fuze, that's what mine was doing, throwing the 40A breaker.
But yours wasn't throwing it when you had those melting wire moments near the ignition so WTF do I know?
I don't know where the PC3 piggybacks on the system either, but would think that the TPS output would plug into it.
You've got easy access to way more good live music than round here that's for sure.

 

[Motorbikerx]

OK!
Think I've found the cause of the rough running at least.
Just checking ignition wires and the main earth when I noticed a tear in the new throttle body adapter(boot)
Same place as the old one was torn.
This is the 'new' part from Witchdoctors....now would old stock rubber parts deteriorate while sitting on a shelf?
The rubber boot is quite thin where it broke and with Torque Tubes the throttle body and attached Torque Tubes do move around a fair bit at idle...
Look at pic and you'll see why it was running so badly!
I better email and/or ring Witchdoctors and see what they can do about it.

 

[Obi Steve]

Well that's disappointing but easier to troubleshoot and repair than intermittent electrical gremlins at least.
Nothing to lose by wrapping with self fusing rubber tape with an overcoat of silicone.

 

[BBob]

I hope you've found the culprit so you can fix it but I found something you may want to watch. Mike, in this video, is a personal friend, who now does repair videos. He does this on the side and he's an instructor by trade. He talks about the injectors and how the air flow at idle is metered different at idle than it is at above idle. Mike is a much better mechanic than I am or will ever be. Anyway, FWIW here it is. I've set it to the part I'm referring to.

 

[Motorbikerx]

Well that's disappointing but easier to troubleshoot and repair than intermittent electrical gremlins at least.
Nothing to lose by wrapping with self fusing rubber tape with an overcoat of silicone.

Will that rubber tape, handle fuel ? That's the stuff plumbers use, and farmers on irrigation pipes that split isn't it, it's good with water but what about fuel?
Maybe a good idea to beef up over the stock intake , cos it's obvious the stock unit ain't up to the job

 

[Chattanooga_Mark]

That’s a big tear for a brand new throttle body adapter. Certainly not the result of use as its mechanical damage. Was it caused from multiple installation/removal cycles, the clamp being too tight or mechanical leverage from the Torque Tubes? Likely a combination of all three.

Many rubber parts we get ‘new’ today have likely been on a shelf somewhere for years. The taillight trim rubber piece that just came in from Polaris was rolled up in the original packaging bag instead of being layed out flat. It had that ‘old’ in nos feel and appearance. Sort of like how a past it’s prime chocolate bar gets a powdery look and feel to it. I removed it from the bag, layed it out flat and will treat it before installation. By treating it I mean I’ll rub in a thin coating of petroleum jelly or a black rubber trim renewal cream. I’ve used a Meguiar’s Ultimate Black plastic restorer previously and it works great. Old powdery looking rubber bike parts look like new again. I used it on the nos heated grips I installed on the Hard-Ball because they also had that ‘old’ look and feel when I removed them from the original packaging. Some of the H-B wire harness sheaths that run along the handlebar needed a few applications.

Even still, a five year old rubber throttle body adapter sitting on a warehouse shelf should have a better life than one being installed on a bike going through multiple heating and cooling cycles.

 

[slickvic]

Yeah that TB boot is definitely the rough run culprit. Now to find that elusive shorted wire !
I’ll tell you….. I’ve been down 3 times. All of which turned out to be something different causing the same issues. Nothing is more frustrating…. Thinking you figured it out. Got it running good again and then having the same issue present it’s self down the road.
you will find it. Don’t let it beat you. It’s always just a process.

 

[Motorbikerx]

That’s a big tear for a brand new throttle body adapter. Certainly not the result of use as its mechanical damage. Was it caused from multiple installation/removal cycles, the clamp being too tight or mechanical leverage from the Torque Tubes? Likely a combination of all three.

Many rubber parts we get ‘new’ today have likely been on a shelf somewhere for years. The taillight trim rubber piece that just came in from Polaris was rolled up in the original packaging bag instead of being layed out flat. It had that ‘old’ in nos feel and appearance. Sort of like how a past it’s prime chocolate bar gets a powdery look and feel to it. I removed it from the bag, layed it out flat and will treat it before installation. By treating it I mean I’ll rub in a thin coating of petroleum jelly or a black rubber trim renewal cream. I’ve used a Meguiar’s Ultimate Black plastic restorer previously and it works great. Old powdery looking rubber bike parts look like new again. I used it on the nos heated grips I installed on the Hard-Ball because they also had that ‘old’ look and feel when I removed them from the original packaging. Some of the H-B wire harness sheaths that run along the handlebar needed a few applications.

Even still, a five year old rubber throttle body adapter sitting on a warehouse shelf should have a better life than one being installed on a bike going through multiple heating and cooling cycles.

More than five year old.
Those TB boots we're updated after 2008 weren't they?

 

[Chattanooga_Mark]

Updated yes, though I’m not sure exactly what ‘updated’ means. Materials? Design? No idea.
Here are pictures of before and after on the rubber airbox seal:

The top picture may not have picked up what it truly looked and felt like. The rubber was as gray as it was black and it had that powdery feel. After rubbing in some of the Meguiar’s product it looks and feels much better. The nos rubber throttle body adapter I have looks and feels good. But I still rubbed in some of the restore cream.

Both o-ring seals looked and felt new so I didn’t apply anything to them.

 

[Obi Steve]

Did you try checking the

Will that rubber tape, handle fuel ? That's the stuff plumbers use, and farmers on irrigation pipes that split isn't it, it's good with water but what about fuel?
Maybe a good idea to beef up over the stock intake , cos it's obvious the stock unit ain't up to the job

Good question, I'll set some up and wipe some petrol on it later this morning. This is making a metal plate, pipe and Ortec hose connection look better all the time.
I had a chat to Marco about this a couple of weeks ago but he's flat out making alloy swingarms for Yamaha thumper MX bikes at the moment.

 

[Motorbikerx]

Did you try checking the

Good question, I'll set some up and wipe some petrol on it later this morning. This is making a metal plate, pipe and Ortec hose connection look better all the time.
I had a chat to Marco about this a couple of weeks ago but he's flat out making alloy swingarms for Yamaha thumper MX bikes at the moment.

I think you're on to something there!
Fabricating a better "Intake Manifold" for want of a better term "wouldn't actually be rocket science"
now would it?
Also it'd be good to be able to compare the 100 cube Intake Manifold(TB Boot) with the 106 item.
See if there's any difference in orientation in critical areas and also construction.
The thick plottens!

 

[Motorbikerx]

New Witchdoctors TB Boot is totally shot...dunno what the answer is there...they're Tryna blame it on cracked throttle plates or some crap.

Anyway my bike electrician mate has been and gone , we spent a couple of hours pulling handlebar switches apart trying different thinks to make the bike do the problem and not do it, by our intervention...
No luck there.
Holger reckons it the Red/Black wire that goes to the relay.
However we can't work out how to pull the fuse/relay box apart, anyone know?
Also looking at the wiring diagram on my laptop computer is an exercise in madness, trying to get it big enough to read as well as move it to follow wires is impossible.
I need to get a hard copy printed out for when he comes back, as well as actually be able to locate certain components as the sit on the bike, I presume there's a page to copy concerning that in the manual that's on Rylans website TVS.
SO the Yellow Bird not gonna be flying anytime soon.
2.34pm and I haven't eaten!

 

[Chattanooga_Mark]

Stress cracks from an overly tight clamp maybe? But that’s a ton a damage on a new part. Therefore, I’d guess the item was somewhat dry rotted prior to installation.

 

[Obi Steve]

I think you're on to something there!
Fabricating a better "Intake Manifold" for want of a better term "wouldn't actually be rocket science"
now would it?
Also it'd be good to be able to compare the 100 cube Intake Manifold(TB Boot) with the 106 item.
See if there's any difference in orientation in critical areas and also construction.
The thick plottens!

Didn't get t o test that. Got a bush fire call out and spent the afternoon driving a 7 tonne off road truck around a mountain, drove for over an hour after we left the last dirt road, finding our way out after dark after most of the fire was out was a challenge. Got home at 9pm.

Going back tomorrow early, to escort a dozer while it cuts a break around remaing hot spots.

 

[Motorbikerx]

You be careful out there Steve.
Ive been checking a few things as much as I could referencing the wiring diagram from the TVS site.
I set multimeter to buzz for continuity and tested the Red/Black wire from kill switch to connector and got a buzz.
then from connector to the 4th pin on the Stop/Tail light Control at the end of the ECM and got a buzz, which would indicate continuity on the Red /Black wire that Holger thought was broken...Dunno why he thought it was broken, too late to call him...he was wondering where the Red/Black went to further down the wiring as he thought it was the problem.
It also goes to the Start button.
Anyway I'm stumped now as I dont know what I'm doing.....
Tomoz Im gonna try to get someone to print out a hard copy of wiring diagram on a large piece of paper so when he comes back he can use it.
He is totally computer illiterate and my laptop is pretty crappy and difficult to control even for me trying to follow wires on a diagram.
bikes looking a mess right now and its very disheartening to even look at it.
Upside is Ive actually got my hearing aids in so I can hear the multimeter buzz, just shows how fkn deaf Ive become...

 

[MagVic CCT]

Don't forget to roll up your hose!