Engine cuts out when gear shift is engage.

DBT

DBT

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Jun 30, 2017
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Hi people. Thanks for the help with setting up my Power Commander, the engine is running beautifully now but I can't test ride the bike. As soon as I kick it into gear the engine dies. I've bridged the side stand cut out switch wires and it makes no difference. There seems to be two items under the seat that are referred to as cut-cut switches. One has three wires going into it and has "UP" molded onto it. The other is a solid state piece that has five black wires going into it and a sticker that reads "tilt switch." If I tilt the three-wire UP switch the engine cuts out, so I am presuming that is working okay. I'm wondering if the solid-state unit is the culprit. I presume this is the tip over switch unit on the wiring diagram. The diagram indicates the side stand switch feeds into this unit. I am hoping this is not the problem as I don't like my chances of getting one from the new Norton. Any help would be appreciated. Thanks people, Dan
 
On the side stand switch connection block ( on bout the swinging arm ) it has 3 wires , it’s the outer two wires that need a link in to hook them together, just saying ! ( I know this from experience, my switch got covered in oil ) if u have already done this then many apols !
 
I quote from @DBT the OP..

"I've bridged the side stand cut out switch wires and it makes no difference"
 
cliffa said:
Have you checked the clutch lever switch?
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This must be OK if he can crank it up and get it started ? If the clutch switch was bad it shouldn't crank when he pulls the clutch lever in to start up.
DBT said:
Hi people. Thanks for the help with setting up my Power Commander, the engine is running beautifully now but I can't test ride the bike. As soon as I kick it into gear the engine dies. I've bridged the side stand cut out switch wires and it makes no difference. There seems to be two items under the seat that are referred to as cut-cut switches. One has three wires going into it and has "UP" molded onto it. The other is a solid state piece that has five black wires going into it and a sticker that reads "tilt switch." If I tilt the three-wire UP switch the engine cuts out, so I am presuming that is working okay. I'm wondering if the solid-state unit is the culprit. I presume this is the tip over switch unit on the wiring diagram. The diagram indicates the side stand switch feeds into this unit. I am hoping this is not the problem as I don't like my chances of getting one from the new Norton. Any help would be appreciated. Thanks people, Dan
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What year and model of 961 do you have ? I think we need to do some troubleshooting , and look at schematic. But if it thinks the side stand is still down then it will kill when you put it in gear. We have to be sure that the wires going up from the side stand switch are continuous . What other work did you do that may be related to this ?
 
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BLIGHTYBRIT/SF said:
On the side stand switch connection block ( on bout the swinging arm ) it has 3 wires , it’s the outer two wires that need a link in to hook them together, just saying ! ( I know this from experience, my switch got covered in oil ) if u have already done this then many apols !
Click to expand...
Thanks Blighty, I had linked all three wires together but thanks for your advice as now I have linked only the two outside wires. Still not working but one step closer.
 
TonyA said:
This must be OK if he can crank it up and get it started ? If the clutch switch was bad it shouldn't crank when he pulls the clutch lever in to start up.

What year and model of 961 do you have ? I think we need to do some troubleshooting , and look at schematic. But if it thinks the side stand is still down then it will kill when you put it in gear. We have to be sure that the wires going up from the side stand switch are continuous . What other work did you do that may be related to this ?
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It's a 2015 model Tony. I have two schematics but neither is exactly the same as the harness in the bike. I have been digging around in the throttle position sensor wiring hooking in the Power Commander and feel I may have caused a fault here as the side stand cut out and the TPS both feed into the solid state tilt switch unit. Please note, this is not the actual cut out switch which has three wires and still works - insofar as the engine starts and runs and will cut out when the three-wire switch is tipped on its side. The little black box directly below the actual tilt switch (confusingly) has a sticker on it that says 'tilt switch' and has 8 black wires going into it. I am thinking the problem lies there. When the 8 wire plug is pulled, the bike won't start. I have also disconnected the PC and reverted everything back to original. The bike still starts and runs but cuts out with moving into gear - which it wasn't doing before I fitted the PC.
 
DBT said:
It's a 2015 model Tony. I have two schematics but neither is exactly the same as the harness in the bike. I have been digging around in the throttle position sensor wiring hooking in the Power Commander and feel I may have caused a fault here as the side stand cut out and the TPS both feed into the solid state tilt switch unit. Please note, this is not the actual cut out switch which has three wires and still works - insofar as the engine starts and runs and will cut out when the three-wire switch is tipped on its side. The little black box directly below the actual tilt switch (confusingly) has a sticker on it that says 'tilt switch' and has 8 black wires going into it. I am thinking the problem lies there. When the 8 wire plug is pulled, the bike won't start. I have also disconnected the PC and reverted everything back to original. The bike still starts and runs but cuts out with moving into gear - which it wasn't doing before I fitted the PC.
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Did the bike come with the SC Typhoon ECU ? I think you have the OMEX because of the tilt circuit unit. You either have a conversion to OMEX or you have a very late model 2015 that started using the OMEX again like a 2016 MK2 961 . I have to find this schematic. But long story short , you need to ohm out the wires leading up from the side stand . Once you find them ohm through the switch , you may have severed a wire . Go back to where you made the cut in to the TPS !
 
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@DBT

Not sure if this helps. As I mentioned to you - I did have a spare. It's part of a complete loom I purchased with all sensors etc. I thought I'd post these pictures here as the wires aren't all just black on this one. Maybe someone can help to identify the pinout from this?

Engine cuts out when gear shift is engage.
Engine cuts out when gear shift is engage.
Engine cuts out when gear shift is engage.
Engine cuts out when gear shift is engage.
 
DBT said:
It's a 2015 model Tony. I have two schematics but neither is exactly the same as the harness in the bike. I have been digging around in the throttle position sensor wiring hooking in the Power Commander and feel I may have caused a fault here as the side stand cut out and the TPS both feed into the solid state tilt switch unit. Please note, this is not the actual cut out switch which has three wires and still works - insofar as the engine starts and runs and will cut out when the three-wire switch is tipped on its side. The little black box directly below the actual tilt switch (confusingly) has a sticker on it that says 'tilt switch' and has 8 black wires going into it. I am thinking the problem lies there. When the 8 wire plug is pulled, the bike won't start. I have also disconnected the PC and reverted everything back to original. The bike still starts and runs but cuts out with moving into gear - which it wasn't doing before I fitted the PC.
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Ah, sounds like you have the patch harness, to convert from SC to Omex.
I've not had chance to test that tilt circuit that I've got here, sorry....but Gojuu having one sounds like a better plan, logistically
 
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Thanks for posting .
Stu Bodycote said:
Ah, sounds like you have the patch harness, to convert from SC to Omex.
I've not had chance to test that tilt circuit that I've got here, sorry....but Gojuu having one sounds like a better plan, logistically
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Did DBT get this going ? I now have the Euro 3 new OMEX schematic and can help trace wiring .
 
@TonyA feedback from @DBT was that the tilt switch unit I sent him got the bike going.

Which also makes me think we need t find out a schematic for the switch unit itself.
 
Hi Gojuu , Is this the
Gojuu said:
@TonyA feedback from @DBT was that the tilt switch unit I sent him got the bike going.

Which also makes me think we need t find out a schematic for the switch unit itself.
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Hello Gojuu , Is this the black flat pack that has tilt switch switch written on it ? This part is eliminated with the SCS Delta ecu. That pack looks solid state epoxy resin filled . With some troubleshooting we can determine which wires need to be low or high for operation. Then with some jumping at least the owner can get the bike going again . Is this part no longer available ? This is worth the effort because many 961's use that thing .
 
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TonyA said:
Hi Gojuu , Is this the

Hello Gojuu , Is this the black flat pack that has tilt switch switch written on it ? This part is eliminated with the SCS Delta ecu. That pack looks solid state epoxy resin filled . With some troubleshooting we can determine which wires need to be low or high for operation. Then with some jumping at least the owner can get the bike going again . Is this part no longer available ? This is worth the effort because many 961's use that thing .
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Yep - that’s the part @TonyA. I don’t need one on my bike which was why I was happy to provide a spare to DBT. We don’t as yet know if they are still used in the New bikes, so - as you say - worth the effort.

Part of me wonders if it’s an equivalent part on another bike though - and given the actual tilt switch -I know which brand I’d start with…….
 
The tilt switch is a common part on a great many bikes. Some time ago I replaced it and if I remember correctly I bought it as a KTM spare part, but the same spare part was available for other bikes
 
@Claudio - not the part with UP written on it - but the black potted unit with the 8 pin connector that says "tilt" in the picture above.

You got that part from a KTM?
 
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