2006 Honda Xr650l - Hot Start Issues

[bobl]

Some xr650l s are prone to intermittent ecu failure (google it). I fixed one for my friend that had no spark, until you thumped the ecu. Yeah, I know, only people with old TVs know that trick, but I picked it up on youtube. The ecu is easy to reach, in the battery compartment on the left rear of the bike. Might be worth checking the spark when it won't start. Carry an extra plug, and stick it into the plug cap and look. Fortunately, the ecu isn't that expensive. Cheapo repops are available for less, but I prefer the oem at about $125.

 

[mototireguy]

Some xr650l s are prone to intermittent ecu failure (google it). I fixed one for my friend that had no spark, until you thumped the ecu. Yeah, I know, only people with old TVs know that trick, but I picked it up on youtube.

I've read about that too, ECU solder joints become brittle, vibration can cause intermittent fails during operation.

In my case never ever has the bike hickupped or shutoff during use. And the ECU is far away from engine heat soak. My symptoms are very much heat soak related as the issue only happens within 5-20 minute window of hot engine shutoff.

 

[ScottRNelson]

Some xr650l s are prone to intermittent ecu failure (google it). I fixed one for my friend that had no spark, until you thumped the ecu.

There is a guy over on ThumperTalk who has documented the entire process of resoldering the ECU to fix the problem. I sent mine to him when it died and it was one of two that he had ever seen that couldn't be fixed. He eventually sent me another one that I didn't ask for, but he's a great guy that way.

I think I currently have three of them and really should keep one in the tail pack "just in case". An ECU that has been resoldered is quite a bit more reliable than the original Honda part.

 

[GB500guy]

I've read about that too, ECU solder joints become brittle, vibration can cause intermittent fails during operation.

In my case never ever has the bike hickupped or shutoff during use. And the ECU is far away from engine heat soak. My symptoms are very much heat soak related as the issue only happens within 5-20 minute window of hot engine shutoff.

Actually I believe the CDI solder joint problems are caused by heating/cooling cycles from electrical currents in the module. The modules feel warm after running. Vibration can't really happen since all components are embedded in potting compound. I've repaired nine CDI modules so far as detailed here:
http://advrider.com/index.php?threads/honda-gb500-thread.1170221/page-3#post-30320591

I would definitely swap in a known good CDI from another bike just to eliminate that possibility since it is a known problem in the XRs.

-Bill

 

[bobl]

I've read about that too, ECU solder joints become brittle, vibration can cause intermittent fails during operation.

In my case never ever has the bike hickupped or shutoff during use. And the ECU is far away from engine heat soak. My symptoms are very much heat soak related as the issue only happens within 5-20 minute window of hot engine shutoff.

My friends bike never hiccupped or shutoff during use either. In fact, it ran fine when it would start. Even when I had to thump the box to get spark, it would start and run fine until you shut it off, then no spark. Try the carrying a spare spark plug trick. If you have to wait ten minutes to get it to start, it will only take 3 or 4 minutes to pull the plug cap, insert the spare plug, ground it on the head and turn it over. If it has spark, probably not the problem. If it has no spark, smack the ecu.

 

[RVFRick]

Component leads should be perpendicular to a PCB, get wave soldered, then leads cut. Solder joints should look smooth, uniform and tidy.


Yours looks rough to put it mildly. If that's OEM Honda it's not surprising to see a high failure rate because who knows where else they cut corners. Crap solder, components, workmanship =

 

[mototireguy]

My friends bike never hiccupped or shutoff during use either. In fact, it ran fine when it would start. Even when I had to thump the box to get spark, it would start and run fine until you shut it off, then no spark. Try the carrying a spare spark plug trick. If you have to wait ten minutes to get it to start, it will only take 3 or 4 minutes to pull the plug cap, insert the spare plug, ground it on the head and turn it over. If it has spark, probably not the problem. If it has no spark, smack the ecu.

After considering the many reports of CDI box issues it makes no sense to exclude it as a possibile culprit.

Shopping CDI box replacement options now.

 

[GB500guy]

After considering the many reports of CDI box issues it makes no sense to exclude it as a possibile culprit.

Shopping CDI box replacement options now.

On late '80s early 90s Hondas I've worked on that had CDI ignitions, the tachometer ran off the CDI signal, so if the tach needle did not wink during cranking that was pretty good proof that the CDI was not working. Not sure if the same test applies to your '06.

-Bill

 

[ScottRNelson]

On late '80s early 90s Hondas I've worked on that had CDI ignitions, the tachometer ran off the CDI signal, so if the tach needle did not wink during cranking that was pretty good proof that the CDI was not working. Not sure if the same test applies to your '06.

The XR650L does not have a tachometer. Nor does it need one.

 

[Rumbo Sur]

The XR650L does not have a tachometer. Nor does it need one.

IIRC, the model previous to the XR650L was the NX650 (only sold for 2 years or so) The NX is identical to the Euro version of the NX, the Dominator ... which in fact HAD a tach. This model sold in UK/EU for years.

My guess is that the XR-L wiring harness most likely has wiring for a Tach in the loom. A close reading of the wiring diagram could verify this.

So, if one wanted to, they might be able to trace down the Tach line and see if you get a signal off it ... or hook up a Tach if you want one.

I would agree, you don't need a Tach on that bike but you may be able to check out CDI function using that Tach line, if, it is in fact there on the XR-L and if the CDI runs the tach. You can see the tach on pics of the Dominator, I assume the NX has same set up.

 

[ScottRNelson]

IIRC, the model previous to the XR650L was the NX650 (only sold for 2 years or so) The NX is identical to the Euro version of the NX, the Dominator ... which in fact HAD a tach. This model sold in UK/EU for years.

My guess is that the XR-L wiring harness most likely has wiring for a Tach in the loom. A close reading of the wiring diagram could verify this.

So, if one wanted to, they might be able to trace down the Tach line and see if you get a signal off it ... or hook up a Tach if you want one.

I would agree, you don't need a Tach on that bike but you may be able to check out CDI function using that Tach line, if, it is in fact there on the XR-L and if the CDI runs the tach. You can see the tach on pics of the Dominator, I assume the NX has same set up.

You are really stretching on your logic here.

 

[Junkie]

Regarding Honda and crappy soldering, my 1990 Integra had problems with bad solder joints on the fuel pump relay board. It wasn't too hard to fix, just another example of Honda solder problems.

 

[Sharky]

After considering the many reports of CDI box issues it makes no sense to exclude it as a possibile culprit.

Shopping CDI box replacement options now.

The XRL thread on ADVrider is a solid place to find advice on no start issues for the XRL. Seems like the CDI is where most people start when weird problems/electrical no start conditions begin to appear. I'd get another CDI box to try and eliminate that possibility. Not because I like throwing parts at problems, but it seems like everyone with an XRL should probably have a spare CDI anyways.

 

[ScottRNelson]

The XRL thread on ADVrider is a solid place to find advice on no start issues for the XRL.

While there are a few good XRL threads on AdvRider, ThumperTalk is a better place to get advice. They don't have threads that go on for many thousands of posts to dig through on TT.

 

[mototireguy]

DB Electrical CDI box replacement installed today.

https://www.dbelectrical.com/produc...-xr650l-motorcycle-1993-2014-nx650-88-89.html

Bike starts up just fine when cold like before. Will update with hot-start results in the days ahead. Fingers crossed this is it.

 

[OaklandF4i]

DB Electrical CDI box replacement installed today.

https://www.dbelectrical.com/produc...-xr650l-motorcycle-1993-2014-nx650-88-89.html

Bike starts up just fine when cold like before. Will update with hot-start results in the days ahead. Fingers crossed this is it.

arty at the very least you will be able to cross off one of the possible electrical issues.

Threads like these are better than reading a murder mystery. Cant wait to hear what the final diagnosis is.

 

[mototireguy]

Update:



Had hot start fail episode today.

No big deal as any bump start immediately gets the bike started.

Next step, investigate the Pulse Generator, maybe roll the $45 dice on replacing.