What other mods to the bike are done? Can you change modes at all? Can you turn the system to OFF? Are there any FI error codes being reported? What lights though? There should only be the LCD indicators and no actual lights associated with the traction control system.

Something is fishy with this as the ECU would report an error with the system if the sensors are faulted. The only time I've seen this type of issue is when using the Woolich harness to flash the ECU on the bike. The interface box places the ECU into "maintenance mode" through the diagnostic terminal. It shouldn't happen under normal circumstances.

 

No major mods, Power Commander and quickshifter only.
Cannot change modes at all, cant turn the system off, no FI codes as I cannot access diagnostics. Yes, it is the lCD indicators that are flashing, no lights flashing.

 

Is the bike an ABS bike by chance?

If so, did you happen to disconnect the ABS module?

 

Good thought as well!

 

It could also be the handlebar switch. The cluster sends the switching signal to the cluster first. The cluster tells the ECU to change modes. If that fails, it errors out.

 

Check your connections at the ECU, specifically the green/red wire on the black connector, right next to the red/green wire. I had a similar situation while I was messing with my ECU harness

 

I have just spoken to a guy who builds superstock zx10s for BSB and he seems to think that it could be the hoses around the throttle bodies.
I will check that tomorrow and the connections at the ecu.
Head scratcher...!!

 

Hoses around the throttle bodies? The hoses that carry air in them? They're the ones interfering with the completely electrical traction control system? OK. :shady: Won't hurt to check them I suppose.

I will be real interested in what you find as the solution to this. It's certainly not a problem many have encountered.

 

I have to call BS on the throttle body lines... Unless its something like the motors for the throttle plates themselves I think your problem lay elsewhere. But I've been wrong before.

To me the first thing that stuck out was it was an ABS bike, but the ABS module was removed. That puts the bike in safety mode and causes the symptoms you described.

The next thing I thought was possibly an ECU interface issue along the lines that Sky mentioned. With the Woolich stuff, sometimes when the bike is first turned on you'll get those symptoms. But usually after starting the bike up, turning it off and starting it back up, it sorts itself out.

The next thing I would look at is the wheel speed sensors on the front and back. I've had a person who replaced his wheels the same time he did an ECU flash and he forgot to install one and it caused a similar issue. So I'd look and see that they're clean and the air distance between the sensor and the TC ring is okay.

After that I'd look at the bar controls, connectors, wiring and finally the ECU.

 

Check your wheel sensors and the tc ring. If you recently had the front tire off make sure it was put on with the tc ring on the right side. All of these things will lead to what your describing. Good luck.

 

OK, bikes been on the dyno today.
The traction indicators were flashing when we switched the ignition on. We took apart the handlebar switch, could not see any issues. Put the switch back together and turned the ignition on, traction indicator now remains on and does not flash! Must have been someting with the switch.
Ran the bike up on the dyno and it would not pass 8k. Took tank off and had a look at connections, all looked good but noticed a slight kink in the fuel hose which worsened everytime we fitted the tank. Tried a dyno run with the tank propped up and fuel hose straight. Bike ran fine. Removed and swapped the hose. Thankfully the bike worked fine.
Couple of questions for you guys.
When the bike was on the dyno, the traction indicator was flashing again. The dyno operator said it is because the front wheel is not spinning and the traction indicator flashes to say theres a fault. When the dyno stopped, we switched ignition off and back on, the traction indicator now remains on. Anyone else experienced this?
The rev counter on the dash no longer works. we believe the signal comes straight from the ecu to the dash. We have ran continuity tests on these cables and cleaned up the connections inside the pugs. The dash works fine but we just cannot get the rev counter to work. Think it may need a new dash? I am going to get my friend to plug my dash into his bike to see if the issue is with the dash or the wiring.

 

The TC lights flashing in error is common when the front wheel isn't spinning, or the front wheel is installed backwards and the tone ring is on the wrong side. Your dyno tuner was correct.

The fuel lines being pinched from the tank has happened to others before. Please take some pics and post them up to show what was kinked and how you fixed it so we can guide others in the future.

Not sure what to tell you on the dash. Trying another dash will help you identify or eliminate it as the problem. The RPM, speed, etc. are communicated from the ECU to the dash through a protocol called CANbus. It uses 2 wires to send a bunch of information, similar to how you can plug in a coax cable that is 2 conductors and get 1000's of TV channels from the cable box.