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Correcting E1 & E4 errors on the air controller.
  Author: Auton
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Air Controller Error E1 & E4 Repair Procedure
Approved by The Venturers Technical Advisory Committee


This repair was carried out on a 1985 Venture Royale.

The first indication of a fault is the air controller displaying an E1 or E4 error. There may be other errors depending on which connections are not working.

Remove the false petrol tank cover

Disconnect battery by removing connectors off one terminal. Pull leads away from terminal wrap in rag. Place second rag over battery to prevent any chance of short circuit.

Remove the access panel.

Remove the 4 screws that hold down the air controller cover, slide cover towards bars to release base.

CHECK THE WHITE CONNECTOR IS FULLY PLUGGED IN and there is no stress on the wiring with cover in place.
 
If connector was loose reconnect battery and confirm error has gone, put a little force on the connector cable in a clockwise movement to confirm fault is no longer present. Reassemble and smile.

If fault is still present then continue as below.

Disconnect battery once again and cover with rags to prevent short circuit.

Disconnect wires Black and Red, these will require holding the cable each side of the connector and giving it a good tug to break joint. Push in release tab on the main white connector (midway on long side of connector) and pull out plug from the controller.

Undo 4 small nuts at rear of controller and remove brackets, support the controller on the display side to avoid dropping it on the ground. Carefully slide the controller out from the panel, watch the rubber seal is coming away clean to avoid breaking the seal.

Place controller "display down" on clean newspaper on your bench, remove small clip on side of controller, removal is easy with a pair of long nose plyers through the raised clip. Remove the two small screws.

Lift cover off back of controller to expose circuit board, undo 4 screws holding down circuit board half way out. Push board down close to each of the sealed screws to break the seal. When done fully remove the 4 screws.

Disconnect small white connector that connects the two boards together. Use long nose plyers to force connector apart a fraction at each end, repeating until it becomes free. You will have to hold the top circuit board while you disconnect this connector. Try not to stress the connecting wires.

Turn board over to show circuit tracks and solder joints. Note the dust on my board, brush off any dust with a horse hair brush (paintbrush), DO NOT USE NYLON OR PLASTIC BRUSH as this may cause static electricity that will destroy the internals of the integrated circuit  (IC) on this board.


Using a magnifying glass, have a close look at the solder joints that are connected to the large white connector. If you see tell tale rings halfway up the joints then you most likely have found the source of your errors. While you have it apart it is recommended that you re-solder all the 9 connections on the plug.

Using a small iron with resin cored solder apply a little new solder to each joint and confirm the joint is shiny. If dull then iron may be to hot.

If you are not keen on doing this soldering then take the board to your local electronics shop to have the work done.

When finished clean up extra flux with needle between all the tracks and connections. Check for any solder bridge between pins or tracks and remove. Use a magnifying glass to check your (Their) work. Brush board with horsehair brush (paintbrush to remove any small dots of solder.) Note the joints highlighted in the following picture. My controller had a number of broken joints.


Soldering hints.
NEVER USE ACID FLUX ON CIRCUIT BOARDS.
Use a damp rag to clean solder iron tip.
Always clean and tin (put small amount of new solder on the iron to allow heat transfer) for each joint.
Apply heat to the biggest object (the connector pin ) for 2 seconds then apply new solder to get good melt.

 

Reverse procedure to assemble.
Reconnect small white connector.
Tighten down 4 screws to hold circuit board in place.
Replace cover.
Re-clip at side.
Tighten 2 small screws on case.

Take to bike and plug in large white connector.
Carefully reconnect battery and recover with rag.

Switch to acc on key.
Confirm error has gone and try manual operation of front and rear pressure. If all is well turn off key.
If things are still not working and Errors still appear then something serious is amiss and you are best to look for another controller.
Disconnect battery once again cover with rags as above for safety. Disconnect white connector.

If all is working as it should be with no errors.
Insert controller back into panel, taking care to make sure seal is installed correctly.
Install 2 brackets and the 4 nuts to hold in controller.
Reconnect connectors Black - Red and main white connector.
Reinstall air control panel slide panel to rear and align and install (4 screws) checking that the cable to the white connector is not under strain.

Install coolant cover panel.

Reconnect battery and confirm air controller operation is correct with no errors.

Install dummy petrol tank cover.

Reset your clock.

Enjoy your new ride.

Any problems or questions contact neville
Venturer name "auton"
autons@xtra.co.nz


TAC NOTE: One of thing first things to check is the plug connections for any corrosion, bent pins, opened ports or push out pins before you dive into the controller.

Last update: 10:15 AM Monday, December 19, 2005

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