Crank position sensor / Pickup sensor - Road Star Warrior Forum : Yamaha Star Warrior Forums

Reply
 
LinkBack Thread Tools
Old 05-12-2006, 09:37 AM   #1 (permalink)
 
Join Date: Apr 2004
Posts: 1,931
Default Crank position sensor / Pickup sensor

I think we need a sticky for this topic it seems this topic is popping up on a daily basis and causing a lot of grief for some people who have numerous failures.
We should try and "stay on topic" and post pics of the install and the symptoms of a bad sensor so we know if and when our Warriors might have a bad sensor.
The obvious problem is the engine just dies and you get a code 12 on you gauges.
The other problems seem to be that the engine just starts running erratic at certain rpm's.
Feel free to post up your bikes specific problems/ how it was acting when your sensor went bad.
I will post upsome pics that redhorse posted up for us several months back as well as some pics from jamesd's 3rd cps failure and fix to get the ball rolling.
Post your pics if you have some so everyone can benefit .
It seems that some sensors are experiencing broken wires at the end of the sensor where the wires connect and the thought seems to be that when installing the sensor there should be a little slack left at the end of the sensor wires to keep them from pulling on the solder joints and breaking from excessive tension or vibration. Or it's just a faulty design. Jamesd actually had the bracket break off on the tabs that hold the sensor to the case, that's a new one. I would suggest applying High temp silicone to keep the wires from vibrating and breaking. You might be able to use epoxy but no one has tried it yet. Spray it with brake cleaner or clean it up with some sort of solvent to make sure their is no oil residue on the plastic first so the silicone has a good clean surface to stick to . Clean the oil residue off your threads of your screws and the threads where they screw in and use loctite. Remember loctite wont work if you have oil all over your threads. This is my solution to the broken wire problem. Maybe you want to do this as a preventative type thing before you get stuck on the side of the road. just order a new gasket first. I dont work for Yamaha so do this at your own risk. Any other thoughts on this problem feel free to post up.
The part#'s for all years from 2002 to 2006 is 5px-81670-00-00 pick up assy.
The gasket # is 5px-15451-00-00.

Insert Image:

96.87*KB

Insert Image:

57.69*KB

Insert Image:

72.02*KB

Insert Image:

60.68KB broken tabs on jamesd's bike this is a new one

Insert Image:

83.16*KB CPS SENSOR

Insert Image:

66.89*KB Sensor with silicone

Insert Image:

63.01*KB Apply silicone

Insert Image:

93.99*KB Sensor installed with wire holders
xharleyrdr is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 05-12-2006, 01:06 PM   #2 (permalink)
Senior Member
 
Badger's Avatar
 
Join Date: Nov 2004
Location: Basingstoke, UK
Posts: 2,386
Default Re: Crank position sensor / Pickup sensor

I had a CPS fail last year at 4,800 miles. I was in the outside lane overtaking when the engine totally died. It was a wire pulled out that caused the problem. When the wrench fitted the new sensor he epoxied the wires to give a bit of strain relief. I haven't done a lot of miles since but holding up fine so far.
Badger is offline   Reply With Quote
Old 05-12-2006, 02:40 PM   #3 (permalink)
Senior Member
 
jamesd's Avatar
 
Join Date: Sep 2004
Location: Knoxville
Posts: 6,312
Default Re: Crank position sensor / Pickup sensor

I have had two die and they both went all at once. The "Mechanic" said there were no external wire breaks but when he ohm'd it out it showed an open circuit.
__________________
Cops carry guns to protect themselves, not you.
jamesd is offline   Reply With Quote
 
Old 05-12-2006, 10:35 PM   #4 (permalink)
Senior Member
 
Join Date: Mar 2005
Location: Colorado Springs, CO
Posts: 197
Default Re: Crank position sensor / Pickup sensor

The dealership (under warranty) called it the cam sensor....I'm guessing its the same. It would not run between 2500 and 3500 rpm. It happened at about 4000 miles. What was really strange was that it would not be as bad before the motor warmed up.
tiresmoke is offline   Reply With Quote
Old 05-13-2006, 03:18 AM   #5 (permalink)
 
Join Date: Nov 2005
Posts: 158
Default Re: Crank position sensor / Pickup sensor

Just got mine out of the shop 2 days ago for this exact issue. The bike was hesitating/missing badly btwn 2800-3000 rpms. And it only seemed to happen once the bike was warm. Once it was determined I had a bad CPS, the tech said one of the wires was barely hanging on and he was very surprised the bike even ran. My repair was covered under the 1 yr factory wty. Does anybody have any info on what this repair might cost for non-warranted bike owners? My bike had barely 2000 miles when this happened. The dealer also mentioned that the broken wire situation may be compounded by the additional vibration our aftermkt performance mods create. An interesting theory, but my CPS went out while the bike was still stock. Thx xharleyrdr for the post. This info needs to be circulated. I wish I had this info available to me before I dropped my bike off at the dealer. They had my bike for a whole month before they figured out what was wrong with it, and had it fixed. I missed the entire last month of ideal riding weather here in the desert. It's now triple digit weather for me for the next 4 months. Great timing.
marcels06 is offline   Reply With Quote
Old 05-13-2006, 03:30 AM   #6 (permalink)
 
Join Date: Aug 2005
Posts: 364
Default Re: Crank position sensor / Pickup sensor

I just finished the install of my CPS and so far so good. Thanks to redhorse for the post and help. My dealer couldn't figure it out but this site has saved my butt a few times, especially with this one. I took pictures as I went and I'll try to get those up soon. There should be enough help here to walk you through the process if you are no longer under warranty.
flyhigh57x is offline   Reply With Quote
Old 05-13-2006, 10:43 AM   #7 (permalink)
Administrator
 
carknee's Avatar
 
Join Date: Jun 2002
Location: Earth
Posts: 4,863
Blog Entries: 80
Default Re: Crank position sensor / Pickup sensor

Good post!
carknee is offline   Reply With Quote
Old 05-13-2006, 10:45 AM   #8 (permalink)
Senior Member
 
darkstar's Avatar
 
Join Date: Aug 2002
Location: Epping, NH
Posts: 16,372
Default Re: Crank position sensor / Pickup sensor

There is a very good post with pictures and instructions put up by AlanH or at least I think it was him....
__________________

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
darkstar is offline   Reply With Quote
Old 05-13-2006, 09:02 PM   #9 (permalink)
 
Join Date: Sep 2004
Posts: 32
Default Re: Crank position sensor / Pickup sensor

Mine when out last summer with a little over 4,000 miles on it while on a trip in Colorado. The bike would not go over 64 miles an hour without missing badly. Fixed under warranty. They did not have the part in stock so they repaired the break. Its been fine since, I now have 8,000 miles on the bike.
barneyfife is offline   Reply With Quote
Old 05-13-2006, 09:39 PM   #10 (permalink)
Senior Member
 
messx03's Avatar
 
Join Date: Sep 2005
Location: The Lake
Posts: 4,338
Default Re: Crank position sensor / Pickup sensor

After putting the cover back on will I need to adjust the clutch lever and if so , how much??
__________________
" Everybody has a plan, till they get hit in the mouth"
Mike Tyson
messx03 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply

  Road Star Warrior Forum : Yamaha Star Warrior Forums > Warrior Forums > Technical Discussion

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -4. The time now is 03:41 PM.


Powered by vBulletin® Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
SEO by vBSEO 3.6.0
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
RSWarrior.com is an independent Yamaha enthusiast website. Content on RSWarrior.com is generated by its users and RSWarrior.com is not in any way affiliated with Yamaha Motor Corporation, U.S.A.