C42 error. Could this be caused by the battery?

2596 Views 9 Replies 4 Participants Last post by irhino, Mar 1, 2014

irhino

Discussion Starter · Mar 1, 2014

Hey all,

Just joined the forum today. I picked up a 1997 TL1000S on trade just yesterday. It was running fine until trying to start it today.

Because it was raining today, I did what any new proud owner would do, went out and started it to hear it run. Fired it up the first time no problem, second time the Fault Indicator came on. A little research showed me how to put the bike in dealer mode and pull the code.

I am getting the C42 (http://imgur.com/iAPOtzT) error which points to Ignition/Electrical (from what I have uncovered from research). I know this battery hasn't been changed based on what the previous owner told me; could it be this simple?

I have been around bikes for a while, my last one was a 2005 Suzuki Boulevard C90. Those are a breeze to work on since they are all open.

Thanks in advance for your help! (It seems like everything I search for leads to this forum! A great wealth of knowledge!)

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tlsgazza

· #2 · Mar 1, 2014

When mine threw a C42 it was the ignition switch that was faulty.
After a lot of playing around with the wiring etc I couldn't sort it,
In the end I bought a second hand switch off eBay, took it apart and swapped the key barrel over so that I kept the original key.
Fitted it and problem sorted,
it could just have been a broken wire or such that was the problem, the ignition switch has a resistor or something that the ecu reads when you turn it on, if it it can't read it it will throw a fault and the bike won't start.

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Six5

· #3 · Mar 1, 2014

tlsgazza said:
When mine threw a C42 it was the ignition switch that was faulty.
....
it could just have been a broken wire or such that was the problem, .....

:stupid

A broken wire or failed solder connection on the circuit board inside the bottom of the switch is the usual cause for this failure.

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irhino

Discussion Starter · #4 · Mar 1, 2014

tlsgazza said:
When mine threw a C42 it was the ignition switch that was faulty.
After a lot of playing around with the wiring etc I couldn't sort it,
In the end I bought a second hand switch off eBay, took it apart and swapped the key barrel over so that I kept the original key.
Fitted it and problem sorted,
it could just have been a broken wire or such that was the problem, the ignition switch has a resistor or something that the ecu reads when you turn it on, if it it can't read it it will throw a fault and the bike won't start.

Do you have instructions on replacing the ignition switch (what needs to come off, where the connections are, etc.)? Also, I would probably end up wanting to keep the barrel as well simply because the original key also unlatches the driver and rear seat.

Thanks!

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irhino

Discussion Starter · #5 · Mar 1, 2014

Six5 said:
:stupid

A broken wire or failed solder connection on the circuit board inside the bottom of the switch is the usual cause for this failure.

Sounds like it's unanimous from what I have read too. Is it pretty easy to replace that switch? Would it be possible to remove it and clean the contacts somehow?

I am going to hop on eBay and order a switch. Should I go with OEM Suzuki or I see EMGO aftermarket for slightly cheaper?

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snowblind

· #6 · Mar 1, 2014

The barrels are easy enough to swap. The hard part is getting the ignition unit off the mount. You'll need the torx security bit plus its loctited in like a b*****d.
However once its off its just a couple of regular cross-heads to get it apart. You may find you can get in clean it up but there are lots around for relatively little money.

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Six5

· #7 · Mar 1, 2014

irhino said:
.... Is it pretty easy to replace that switch? Would it be possible to remove it and clean the contacts somehow?

I am going to hop on eBay and order a switch. Should I go with OEM Suzuki or I see EMGO aftermarket for slightly cheaper?

If the problem is actually INSIDE the switch (it usually is), then it is not a matter of dirty contacts. Rather, something has disconnected - usually where the wire is soldered to the switch contact. The OEM switch can be repaired, but it involves drilling the rivets that hold the bottom cap in place. Once the cap is removed, the connection can be resoldered. Then the cap can be reattached with screws - the self-tapping type, or another sort.

The EMGO switch is a good plug-n-play unit. However, the EMGO key is completely different from the OEM key - not interchangeable. The one key will not fit into the barrel of the other. Therefore, I doubt if the barrels are interchangable between the two brands, but I can't say for sure.

A few photos to help you visualize the assembly....

Key with barrel and tumblers (wafer discs)....

Inside the switch housing where barrel fits....

The Torx bit needed to remove the switch from the triple clamp....

The bottom cap and rivets....

The top cap and screws.....

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irhino

Discussion Starter · #8 · Mar 1, 2014

Thank you all for your replies. I can see how this forum is invaluable. There are a few aftermarket parts that seem to be tapped in to the ignition wires, the wires hooked in to the black wire had a bad connection. So I have ruled out the switch being bad but I am going to have to take some things apart to lengthen and re-solder the connections. I am happy it was that easy and I might just end up getting a new switch altogether to avoid the hassle in the future.

I used a temporary jump wire for now to test it as shown below:
https://www.dropbox.com/s/mo2ovuji0bqsf02/2014-03-01 13.01.15.jpg

Guess I could also include a few picture of the bike.
https://www.dropbox.com/sh/881ypvslg2oa15b/cyUM_I8--A

Thanks for your help again. I look forward to being a contributing member from here on out.:thumbup

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tlsgazza

· #9 · Mar 1, 2014

Nice one.
Well, I did say it could just be a broken wire, :thumbup
Ps: fill in your profile as well, you could be living in Timbuktu for all we can tell..
:lol

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irhino

Discussion Starter · #10 · Mar 1, 2014

tlsgazza said:
Nice one.
Well, I did say it could just be a broken wire, :thumbup
Ps: fill in your profile as well, you could be living in Timbuktu for all we can tell..
:lol

Ha! Look at you with your guesses....I do live in Timbuktu! Only kidding. I am in Utah. Have been lucky enough to live and ride in Hawaii....I kind of miss the year round riding. Thanks again for your help; profile has been updated.

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