02 R1 over revving and electrical problem

Hi there Problem I have is my 02 R1 is over revving, it is stuck at 4000rpm. It isn't idle adjustment as thats adjusted fully and not my throttle cable as that has plenty of freeplay, could it be something electrical? and if so what? Also, when my ignition is on and my lights are off I pull in my front brake and my instument cluster background light comes on, could this be part of the same problem? Can anyone help me as I have just put in my new barnett clutch, new stator:) and now I have this!:nopity: :chair: Jason

sounds like electrical to me jas. im guessing all your fuses look fine. does the bike stay at 4k even after you start it or just when you turn it on. is the light symptom persistent or are both problems seperate incidents going back & forth?

sounds like electrical to me jas. im guessing all your fuses look fine. does the bike stay at 4k even after you start it or just when you turn it on. is the light symptom persistent or are both problems seperate incidents going back & forth? Stays at 4k, even after warmed up. Light is persistant, same as rpm. Has this problem before when I had my headlights off and started my bike, connected my headlights and the rpm dropped, but my lights are connected amd work fine, this was before I changed my stator though so not sure if the fact that my charging system is working now amd putting 14+ volts in the system has made a difference and heightened the original problem. As the brake lever/display light problem has been there for ages Not sure why its over revving? Jason

Well......the lighting problem sounds like a ground issue. When a ground connection is loose somewhere, the power going to one circuit has to find itself a path to ground, usually through another circuit...... such as your brake light causing the instrument light to come on. A bad ground connection can cause all sorts of errors, including interference with all of the signals going into and out of the ecu; so yes, this could also be the cause of your revving problem, though I doubt it. The 2002 R1 computer cannot control idle speed, the computer has no control over the airflow into the engine (most cars with efi have IAC valves, that the computer uses to regulate the air through the throttle body at idle. The R1 has the idle adjustment knob instead, and relies on the computer only for fuel and ignition control). Thus, no electrical problem can cause enough air to get past the throttle bodies to allow the engine to rev that high. More likely would be a vacuum leak somewhere. First, of course I would check the throttle cable, and be sure the throttle is operating all the way without binding. I believe you already checked this, so you need to check for an unplugged vacuum line or a throttle body not seated properly. There are a few vacuum hoses on this bike, the most likely would be the one running to the fuel pressure regulator. Remember, the secondary throttle valves (the slides you see if you look into the throttle bodies) are vacuum actuated. You'll notice if you work the throttle, they won't move. The big housings on the top of the throttle body contain a vacuum diaphragm that opens these slides. If one of the diaphragms is torn, or the line going to it is broken or disconnected, this would also let extra air into the intake. However, with it idling at 4000 rpm, you need to have a fairly large leak. I would guess the fuel pressure regulator is unplugged, or the throttle bodies not seated fully in their boots.

Seems it COULD be my fast idle unit. Going to do some more test with it to see if it is. Only problem is, cant find anywhere that sells these seperately. Still need to find where my electrical problem is

maybe something catching on the cables down at throttle bodies. could be rock or some debris. i would take tank off and airbox and take a look. make sure they are opening and closing all the way by visually checking with airbox off.

:riding :ncont: Problem sorted Eventually it was the fast idle unit! The small medal dowl in the end was not moving freely as it was not shutting the choke mechanism off. Me and my brother narrowed it down to that, so we unbolted it, unbolted the two sections, cleaned and oiled the dowl and its mounting hole. Tested the idle unit with the dowl section off by heating it with a hair dryer and it was working fine, put the whole lot back together and hey presto. R1 back on the road! Could a mod please post this for people who may have the same problem in the future in a relevant section. Thanks Jason

just brought my 03 r1 and has the same problem! gonna copy u and give it a clean up. great post well done.

can you be a bit more specific. witht the task please. i've got a similar problem and i think i also need to clean the fast idle unit.

Remove your tank and airbox Mounted on the throttle boddies (on the left hand side) is the fast idle unit. It has a little dowel on it that pushes a lever on the throttle bodies ( the fast idle) Remove it and dismantle the unit as far as you can and give a damn good clean. Jas

cheers pal