No fuel pump!

[peels]

Finally got time to get the bike back together after the transmission work.. Tank back on everything good, turn key...but, no whirr from the pump I had even bought myself some celebratory whisky for completion lol I was so sad.

Using wiring diagrams, I was able to deduce I am not getting power TO the fuel pump. And since I had so much apart, I can't help but think: wtf did I do!!?!?! Everything was peachy when I took it out.

Relay checks out, fuses not popped, sort of lost on this one. There IS 12v to the fuel level sending wire.

Next step? What am I missing?

Thank you all very much.

[kirby]

Any other electrical problems? Is the stop run switch on the handlebar in the run position. Is the side stand down with the trans in gear?
If all ok try engaging the starter.

I will assume that you are checking for power at the connection from the harness to the tank lead. Pull (if not already) the fuse and check with a meter, also clean the contacts. Swap the relay with one of the others, (same # and interchangeable)
Not know how much you tore into the systems, this is all I can think of off the bat.

[peels]

Any other electrical problems? Is the stop run switch on the handlebar in the run position. Is the side stand down with the trans in gear?
If all ok try engaging the starter.

I will assume that you are checking for power at the connection from the harness to the tank lead. Pull (if not already) the fuse and check with a meter, also clean the contacts. Swap the relay with one of the others, (same # and interchangeable)
Not know how much you tore into the systems, this is all I can think of off the bat.

thanks kirby.

yep, kill switch and sidestand switch both toggled. relays swapped. no joy. Starter works.

I can hear/feel relays kick on when I turn the key. Unsure if its the correct relays clicking could just be motronic?

indeed. checked for 12v at that connector. green/white is pump, and brown is ground. only get 12v from the blue/white. that is fuel level sending.

this one is seriously bugging me today. hate being so close to finishing and something stupid stops me.

first i thought it might be due to tank off sitting on the floor tilted on its nose for 2 weeks.... it almost HAS to be something dumb that I did.

[kirby]

Any other electrical problems? Is the stop run switch on the handlebar in the run position. Is the side stand down with the trans in gear?
If all ok try engaging the starter.

I will assume that you are checking for power at the connection from the harness to the tank lead. Pull (if not already) the fuse and check with a meter, also clean the contacts. Swap the relay with one of the others, (same # and interchangeable)
Not know how much you tore into the systems, this is all I can think of off the bat.

thanks kirby.

yep, kill switch and sidestand switch both toggled. relays swapped. no joy. Starter works.

I can hear/feel relays kick on when I turn the key. Unsure if its the correct relays clicking could just be motronic?

indeed. checked for 12v at that connector. green/white is pump, and brown is ground. only get 12v from the blue/white. that is fuel level sending.

this one is seriously bugging me today. hate being so close to finishing and something stupid stops me.

first i thought it might be due to tank off sitting on the floor tilted on its nose for 2 weeks.... it almost HAS to be something dumb that I did.

Looking forward, the fuel pump relay is 4th from the right. (pull and clean contacts!) Motronic is 3rd from right.
the fuel pump fuse is 6th from the left. its 10 amps, and anything less it will blow. Pull it and check with a meter!!! clean contacts!!!
motronic fuse is # 5 from the left.
It has been my experience that the motronic either works or it doesn't period. If the starter works and you get spark ,its most likely good.(never seen one fail)

[riceburner]

battery low?

what battery voltage are you getting? a healthy battery actually shows more like 13v when measured.

[peels]

battery low?

what battery voltage are you getting? a healthy battery actually shows more like 13v when measured.

yep. had battery on charger in preparation for the "maiden voyage" it was showing 12.91 after my first attempt to start failed-first thing I checked.

turns over beautifully. But fuel pump never wakes up.

[peels]

Went home at lunch... and the good news(as good as it can be) the fuel pump works on bench test....

not getting power to connector.

i THINK i tested correct spots. I got no voltage at relays OR fuse for pump. also, I don't feel motronic or pump relay clicking.


did not have time to bypass the sidestand. I unwadded a few of the wires from the kill switch. no luck. hoping its one of those two things. because after that, I am totally lost.

[kirby]

Did you try and swap the relays? Might be motronic relay. Also could be gulp! the ign sw. Hope its the relay or dirty fuse connection
. Clean them all!!! (important!!)
recommend DeOxit Radio shack may have it. (Good stuff)

If no power to the motronic relay then nothing will work. See if you have spark. Not the load relief relay as that only sheds stuff not needed by the engine.

[peels]

Not side switch

Not pump.

Don't "feel" relays click. Either one. Never see voltage on fuel pump relay terminals.

Don't think it's kill switch. It works as advertised. Starter works on, doesn't work when off. I've removed most of the sheathing to look for linked wires.

Still No 12v to fuel pump connector.

I'm nervous. Not sure what to do here.

[CycleRob]

peels,
Check the fuel pump connectors for wire terminals that are pushed out of position. Easiest way is to try to pull the terminal out of the plastic plug by lightly pulling on the wires, one-at-a-time. About the fuses, a quick way to test them is to swap 2 of the same Amperage - - you can't rely on them looking OK or like new. Same for swapping the relays . . . the 4 small black ones are identical. Lastly, is the brown wire screwed onto the Motronic left side mounting bracket still attached?

[peels]

peels,
Check the fuel pump connectors for wire terminals that are pushed out of position. Easiest way is to try to pull the terminal out of the plastic plug by lightly pulling on the wires, one-at-a-time. About the fuses, a quick way to test them is to swap 2 of the same Amperage - - you can't rely on them looking OK or like new. Same for swapping the relays . . . the 4 small black ones are identical. Lastly, is the brown wire screwed onto the Motronic left side mounting bracket still attached?

Yep relays fuses all swapped.

Unsure what brown wire you mean? will check later today.

[kirby]

That brown wire would kill the ECU if not connected.

[sweatmark]

... the fuel pump works on bench test

not getting power to connector

got no voltage at relays OR fuse for pump

also, I don't feel motronic or pump relay clicking.

Battery(+) ----- junction X9430 ------ Fuse 6 ------ relay K9100 ----- Fuel pump M9100

Battery(+) ----- X9430 ----- Key switch ----- Emergency stop switch ----- relay K9100 ----- Fuel pump 9100

Sidestand switch doesn't matter.
<edit> motronic is ground path for the K9100 relay coil.

1. If you don't have power into Fuse 6, then your problem is more fundamental. Double-check both sides of Fuse 6.
2. With key switch ON, you should have two hot pins (if Fuse 6 circuit is valid).

[peels]

... the fuel pump works on bench test

not getting power to connector

got no voltage at relays OR fuse for pump

also, I don't feel motronic or pump relay clicking.

Battery(+) ----- junction X9430 ------ Fuse 6 ------ relay K9100 ----- Fuel pump M9100

Battery(+) ----- X9430 ----- Key switch ----- Emergency stop switch ----- relay K9100 ----- Fuel pump 9100

Sidestand switch doesn't matter.
<edit> motronic is ground path for the K9100 relay coil.

1. If you don't have power into Fuse 6, then your problem is more fundamental. Double-check both sides of Fuse 6.
2. With key switch ON, you should have two hot pins (if Fuse 6 circuit is valid).

I DO have power to fuse 6. Both sides.

Just checked-no spark either.

I jumped the kill switch for giggles.

I'm unsure how to continue. Aside from opening wallet. Or pushing the bike into the the Mississippi and calling the insurance company lol joking

[peels]

solved!!!during reassembly, I had realized I I forgot something, re-crabbed the frame. Apparently, this dislodged the side stand plug right next to the gear indicator plug! Left side right behind frame rail.

Happened to be going back through all the wires and jiggled that, it came flying back.

Phew!

Thank you gentlemen!' I'll be riding if you need me. Don't care how cold it is lol

[kirby]

marvelous!!

[AZBMWRIDER]

Typical electrical issue, 99.9 % of the time on troubleshooting and .1% fixing the problem !!!!

[peels]

The story didn't quite end there...

Some things i learned.. Should already know really lol... Triple CheCk THEN freak out. Not vice versa, like I did.

2nd.. Even if you're excited to see it work, do not forget to attach fuel line before turning the key. Splash! Lol

Also, I broke the 2nd plastic QD with the 100times I messed with the tank. O rings ate it.replaced, but I had gas on the cat after a short ride... And couldn't tell if it was new or from the original splash... But I was just over it, and had connector in the box. It's Done.


And, headlight lost low beam, but that's easy.(or I hope it is the bulb lol)


As big a hassle as That was, It feels good to know the bike as well as I do after all that...

[peels]

photo evidence of the problem. you can see both ends of that plug, right after I felt it "pop" as I wiggled the sidestand wires....and a funny message I sent my wife. LOL

[towerworker]

So glad you figured it out! ............ya know.....neglecting to change the antifreeze will cause similar problems.......