link
n00b Ruckster
Posts: 5 
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Post by link on Apr 12, 2021 11:13:49 GMT -5
Swapped out my 2003 stock engine (except for the Met Gears) engine with a 2016 last week. New ECU, wiring harness, carb, airbox etc. It's a fairly  stock Ruckus with my custom tweaks around. My Issue: The Temp light is ON as soon as I turn on the ignition key. Troubleshooting:- Flushed and bleed coolant
- Pulled Thermostat
- Inspected everywhere - No leaks
Only remedy to to disconnect the plug that controls it in the battery box. It put me into the 5-7mph 'crawl home' mode but I don't think it actually was due to heat. I think the light being on trigger the 'crawl home' mode. Questions:- Any ideas on why the light is always on?
- Would the 'crawl mode' happen even if the engine was below overheating temp?
- Is the LED Drive Unit that the Temp light plugs into different on a 2016 vs 2003?
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Post by Baizy on Apr 12, 2021 19:13:19 GMT -5
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link
n00b Ruckster
Posts: 5
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Post by link on Apr 14, 2021 9:41:01 GMT -5
Thanks Baizy! I swapped the old '03 Thermostat to the '16 engine and unfortunately, same. The light comes on as soon as I turn the key to ON, before I even start it. Would the 'crawl mode' happen even if the engine was below overheating temp? Could it be the water pump? Any help from the community would be welcomed. |
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Post by Baizy on Apr 14, 2021 17:54:34 GMT -5
link can you clarify what year harness/ecu you swapped to? I haven't delved too deep into the different years but I know things in the ecu change from the 03-05 to the 06+ecu Worst case scenario you have a bum ecu and need a new one. There should be a troubleshooting section in the manual I linked for you to follow that will give you more clues.
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link
n00b Ruckster
Posts: 5
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Post by link on Jun 27, 2021 14:31:05 GMT -5
2015 wiring harness. The light is on all of the time.
Per the service manual, I've tested the wires for a short. Tested that the thermostat works. Checked ect wiring. Tested a 03 ect sensor. Pulled water pump. No blockage or issues.
Nothing shuts the engine light off.
Does the ruckus have a clutch safety switch? I'm beginning to think the clutch is dead.
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Post by Baizy on Jun 30, 2021 17:58:27 GMT -5
Unfortunately or fortunately the transmission is 100% analog so your gremlin lives inside the wiring harness. If I get the time I will see if I can come up with a magical fix.
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Post by livingbyfaith on Jul 23, 2021 2:48:08 GMT -5
Okay, here are some silly questions...
1. What was the condition of the motor you bought? I mean, was the motor purchased after an accident, been in a flood, etc.?
2. Do you have the proper cooling path? Although, I don't think you would have the light on at start up, but just making sure, but it could cause an air pocket.
3. Did you check for continuity on the white wire that connects to the thermostat? Did you check the white wire for continuity all the way back to the ECM? I see you tested for a short, but I don't see anything about continuity of the wire.
4. Could there possibly be an air pocket due to not bleeding the cooling system? I personally think this is a long shot, but just asking!
I personally think you have four possible problems...
1. Coolant Temperature Indicator Sensor Circuit is short circuited. This is the light in the speedometer, but it sounds like you tested this!
2. ECT Sensor Circuit: Open circuit of white wire between the ECM and ECT. It sounds like you may have tested for ground, continuity or both. Not absolutely sure as you just say you tested it.
3. ECT Sensor: Sounds like you tested this also!
4. Faulty ECM: No way of checking ECM itself. Plus, the white wire is the only wire for the ECT sensor that goes to the ECM. There is nothing else for the cooling system. So, if you are sure everything is plugged in correctly and that all of your tests were done correctly it most likely is an ECM issue.
I took hours diagnosing a starter problem and tested everything you possibly could two times. I tested everything the manual stated plus more. Guess what, it was the ECM. So, if you are positive in how you tested everything you may want to see if you can connect with someone who will let you pop their ECM in your unit or purchase a used / new unit. I would personally double check for sanity sake and if everything is the same move to the ECM being replaced.
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