Suspension Controller Fix

Bob Lillis provided me with this fix for my CLASS air-suspension controller on my 87 Venture Royale.  When turning the key to ACC, I would get a E-4 error code on the controller. When I opened the door to access the back of the controller, I could jiggle the electrical connector and eventually the controller would work. I thought I was in for a big bill for a part.
Bob suggested that he had had similar problems that were solved by removing the electronic cards from inside the controller and examining them with a magnifying glass for tiny cracks in the solder. Sure enough six of the pins to the electical connector were cracked. At first I only saw three cracks, but upon reassembly, I still got the E-4 message. Back apart, I took the board and the magnifying glass out into the sunshine and found the other three. A simple touch of the hot solder iron to each of the pins did the trick.
It appears that the cause of the problem was that when my local Yamaha dealer remosved the fairing last year, then misrouted the controller electrical wire under the CB, putting extra stain on the wire and the connector. Vibration eventually took its toll. There is plenty of wire to route it around the CB. Owners may want to check the wire on their controllers to see that there is not excess tension on the connector. Just open the door to the engine overflow bottle and see that there is some slack in the controller connector wire.
......Good riding, Bob Thornton

Last update: 03:27 PM Sunday, September 26, 2004

• Adding Grease Zerks to Early 1st Gen Ventures
• FORK REBUILDING FOR DUMMIES
• SuperBrace Discussion
• Progressive Fork Spring Replacement
• 83-85 Shop Manual Misprint - AntiDive Adjustment
• Loose Damping Bars
• Anti-dive Systems Clarified
• Changing Fork Seals
• Upgrading Rear Shocks
• Progressive Suspension Rear Shock Part No.
• Get That Superbrace!
• Wobble Testing
• CLASS System Overhaul
• Removing The CLASS System
• Air Suspension Woes
• Poor Handling
• Fixing The Wobble