TES Warning Problem

[Stoney]

Here's one I haven't found on the forum yet.  My TES warning has been flashing for a few days. I've had it happen before, maybe 2 or 3 times while changing from solo to 2-up, and it always went away after restarting a few times. This time, no luck. After trying a few different things, I found that the TES fuse was blown.  I replaced it with a new one (15A), hoping that it was just a fluke, but it blew immediately again. I looked for any sign of a wire shorting out, but nothing obvious that I could find. Has anyone else had this issue?  Any ideas where I should be looking? 

[azgman]

Sounds like one of the TES motors is jammed. Disconnect them one at a time and see which one is blowing the fuse.

[Stoney]

I'll give it a shot tonight if I get home from work at a reasonable hour.  Thanks!

[Coconut]

Stoney,

With any problem like this, one of the first things to do is to check to see
if any DTC's ( Diagnostic Trouble Codes ) have been stored.

It's important to do this sooner rather than later as some Codes can be erased
after a certain number of "no fault" starts, so with an intermittent fault the code can be erased
before anyone has had chance to note the code and determine what the fault is ! 

Fortunately it's EASY to display any stored codes on your Instrument Panel 

See this post : Servicing Data, Reference Info. & DTC ( Fault ) Codes
for instructions on how to display any stored codes, and note that at the end of the most recent post
there is a downloadable Word document that I prepared listing all the codes and their meanings 

Cheers 

[Stoney]

Coconut,
Using Dealer Tool, there are no stored codes, and it doesn't appear that there is a test for it to perform on the TES system.  As soon as I get home, I'll be checking the TES motors, as azgman suggested.  However, I'll need to pull out the service manual and find where the heck they're located first!

 

[Stoney]

Well, first off, in attempting to pull DTCs via the instrument panel, I only get P0000.  Ignition off, I then disconnected both front TES connectors at the top of the fork.  I have no idea where the rear TES connector is, and it got too dark to begin disassembling too much of the side plastic to try and find it.  But it must be very hidden, as I looked from all angles to no avail.  Anyway, I thought I'd try a new fuse with the 2 fronts disconnected.  Turned the ignition to 'on', but without starting.  No error message!  Plugged each connector back in (shutting the ignition off first), and started the bike.  Fuse blew immediately.  Ignition off, disconnected the front connectors again.  Now, with the bike completely off, key removed, the fuse blows the second I attempt to install a new one.  Electrical issues are so much fun!  I'll look into it a little more tomorrow, but it's looking more & more like it's headed for the dealer on Saturday.  Yuk.
 

[azgman]

According to the service manual DTCs are not stored for the TES. You would have to have the fault present when the diagnostic tool is hooked to the bike. That said, it should throw a fault if there is something wrong with the system components, but maybe not the wiring. The motors are protected from overload so hopefully, this will have an easy resolution. Look in the SM starting at page 13.22 and then going into chapter 14. 

Keeps us filled in, and good luck!

[Stoney]

Well, the last test that I attempted was unplugging the wiring connector at the TES module, just to see if the fuse would still blow.  It did not, which only eliminates the wiring between the fuse and the module. I'm wondering if somewhere a wire was pinched during the fuel tank replacement (3 years ago) or the cylinder head replacement (last fall), possibly wearing through the conduit after a period of time.  I'll be taking the bike to the shop as time permits, which may not be for another week or more.  Updates as I learn them.  Azgman & Coconut, thanks for the assistance & encouragement!