No fuel pressure...?

[miketherider]

Picked up a 2005 FZ6 from the original owner. Has 4800 original miles. Would not start so picked it up on the cheap.

Original owner let it sit for almost 3 years. Has a brand new battery; checked all connections and main fuses.

First problem was a broken connector at the fuel pump; the green/brown wire on the white connector had broken. Fixed that, which erased the 43 error code. Also had a blown fuse so changed that. Tried to start to no success.

Went ahead and changed plugs, cleaned the intakes and injectors. Air filter was clean.

Still no life. So, I pulled main line coming from the fuel pump. When I hit the button, no fuel comes out.

I dumped some sea foam in the tank when I first brought it home in the hope it would clear out some of the bad fuel in it.

When I first turn the key on, I can hear the pump, but only with my ear close to the tank; it sounds like a bubbling inside. But, still no fuel coming from the pump after I turn it on.

Should I look into a new fuel pump or look to see if the filter screen is clogged? What is involved with getting at the screen? Going to drain it tonight to tear at it tomorrow.

 

[yamihoe]

I would definitely drain the tank and pull the pump out.
If it sat for that long all the good stuff has evaporated and the rest of the gas attracted water. So its probably pretty gummy in there

 

[ChevyFazer]

+1 on what he said its prolly just gummed/clogged up

 

[dxh24]

+1 on the others- Somethings clogged in the fuel flow... I'd expect it just gummed up an injector or the tank outlet... easy fix :thumbup:

 

[FinalImpact]

OK I could be mistaken here but I worked on an 09 yama'r that had a check valve in the fuel line so Fuel will not come out when the line is removed disconnected from its mating part. So, Depending upon WHERE you tried to spurt fuel from, that check valve could have stopped it.

IDK if Yama's placed a check valve on the hose to the fuel rail, but look it over and confirm the valve is not the holding it.

IF you depress it and power the pump, gas is going to fly everywhere so be wise cause you could have a big crisis very quickly!
*** PLEASE BE VERY CAREFUL!!!!! ***

Unfortunately the manual didn't go into much detail about how to check fuel flow volume or pressure. Pg 291, (7-6) of the 07 Service Manual.

 

[yamihoe]

yea deff be wise about testing the pressure.....car FI systems usually run at 50-55+ psi......
and yes the injectors are probably just gummed up as well.

with my nitro engines i dump a bottle of alcohol in the tank and shake it up, then let it sit for a few hours then shake it up again then pump it all out,
the alcohol should make whatever gunk in there liquid again and make it thin enough to go thru the pump without hurting it....just make sure you do it on the correct side of the check valve and DO NOT let that mixture of nasty stuff get into the injectors or motor....

 

[Cali rider]

Here are some pictures here of what the built-in fuel filter looks like:

 

[TownsendsFJR1300]

If it hums upon powering it up initially, that's what its supposed to do. It'll turn off once pressurized. If hooked up on the bike, the kill switch MUST BE IN THE RUN POSITION to work.

Per the manual (page 7-6, 2007 thru 2009 Yamaha shop manual), the pressure is tested by hooking up a gauge to the end of the fuel hose that comes off the fuel tank, disconnected at the other end, where it attaches to the primary fuel rail. 36 PSI is specified.

If the bike is somewhat together, pull the air filter (gas tank hooked up) and spray a little starting fluid down the throttle bodies while cranking (trying to start it). If it trys to start you know there's a problem in the fuel system..


The below picture (from another poster) shows a tab that will disconnect the sender gauge from the pump itself while its still IN THE GAS TANK. It is considerably easier to remove the pump with the two disconnected as it is EXTREMLY TIGHT.

Re-installation does NOT require the two to be apart...

 

[miketherider]

Pulled the fuel pump out. Pretty nasty. The fuel level was very low, so a lot of surface rust has accumulated on the pump as well as the inside of tank. The filter is nasty as is the mechanical pump itself. I might be able to clean things, but going to be tough due it the whole thing just being nasty. Going to flush the tank and try my best to really clean the filter and try it again. Worried some gunk got through to the injectors, so those are likely next. Believe a new (used) pump is in order though.

 

[degake]

Pulled the fuel pump out. Pretty nasty. The fuel level was very low, so a lot of surface rust has accumulated on the pump as well as the inside of tank. The filter is nasty as is the mechanical pump itself. I might be able to clean things, but going to be tough due it the whole thing just being nasty. Going to flush the tank and try my best to really clean the filter and try it again. Worried some gunk got through to the injectors, so those are likely next. Believe a new (used) pump is in order though.

If your tank is just as nasty as the one in this thread, you should be able to get the pump clean again: link :thumbup:

Grtz,


Degake

 

[04fizzer]

If your tank is rusted up and nasty, you may want to toss around the idea of replacing it. The rust will drop off and plug things up again unless you properly clean and treat the tank to seal it.

 

[miketherider]

Update; I pulled everything out, cleaned the fuel pump, then sealed the tank using Caswell (best stuff out there) after cleaning the tank out several times with lacquer thinner and some BBs.

Sealed the tank, then let it cure for several days.

While at it, I pulled the pump completely apart and soaked everything in Yamaha carb cleaner. Took all the plastic bits out after a couple of days and cleaned them with a fine brush. Let the pump itself keep soaking.

Pulled the pump yesterday and tested it with a 12 volt battery. Pump came to life. Tested a couple of times on the bike and off the bike.

Put everything back together and hit the button. Stumbled around, but finally got it to fire. It will idle fine, but as soon as I try and rev it, it starts stumbling, badly.

I put a load of seafoam in and ran that through. Seems to have helped some, but still won't rev cleanly.

Odd part is when it is cold, it runs damn near perfect, at least at idle. Once it gets warm though and idles down, it eventually just dies, then it won't start again until it cools off. Before work, I hit the button this morning and it jumped straight to life and I was able to give it some gas without it stumbling. Managed to get around the block a couple of times, but once it warmed up again, started to stumble.

Guessing I need to look at the injectors next or TPS? No idea if the recall has been done. It's slowly running better, but still has some issues to sort out. I cleaned the butterflys when I had it all apart, so those are spotless. How much fun is it to pull the injectors and clean those?

 

[04fizzer]

Update; I pulled everything out, cleaned the fuel pump, then sealed the tank using Caswell (best stuff out there) after cleaning the tank out several times with lacquer thinner and some BBs.

Sealed the tank, then let it cure for several days.

While at it, I pulled the pump completely apart and soaked everything in Yamaha carb cleaner. Took all the plastic bits out after a couple of days and cleaned them with a fine brush. Let the pump itself keep soaking.

Pulled the pump yesterday and tested it with a 12 volt battery. Pump came to life. Tested a couple of times on the bike and off the bike.

Put everything back together and hit the button. Stumbled around, but finally got it to fire. It will idle fine, but as soon as I try and rev it, it starts stumbling, badly.

I put a load of seafoam in and ran that through. Seems to have helped some, but still won't rev cleanly.

Odd part is when it is cold, it runs damn near perfect, at least at idle. Once it gets warm though and idles down, it eventually just dies, then it won't start again until it cools off. Before work, I hit the button this morning and it jumped straight to life and I was able to give it some gas without it stumbling. Managed to get around the block a couple of times, but once it warmed up again, started to stumble.

Guessing I need to look at the injectors next or TPS? No idea if the recall has been done. It's slowly running better, but still has some issues to sort out. I cleaned the butterflys when I had it all apart, so those are spotless. How much fun is it to pull the injectors and clean those?

I would guess it's still a fuel issue, especially if the sea foam helped.

 

[ChevyFazer]

^^+1 on that if it will idle fine but bogs down when you try to give it gas then something could still be clogged up not letting more fuel into it to run higher rpms. How much seafoam did you put in it and how much has the bike ran with the seafoam in it? Because I imagine putting too much in without actually running it through the engine to let it do it's job could cause the same issue. Or it could be electrical, there is a sensor on the bike wich measures the air temp and adjust the fuel accordingly
, for the life of me I can't remember what it's called right now but that might be acting up if it runs fine cold

 

[Motogiro]

Also the fuel delivery problem may have been solved now and you might test the TPS (Throttle Position Sensor)

If you haven't done this procedure. Search out it out here on the forum. Takes a few minutes. If it's bad it can cause the stumbling on throttle open.

 

[miketherider]

Checked the TPS through the diagnostic mode. Registered 15 when closed and 100 when open, which is right in the spec range (high end of them, but still within them). Pulled the VIN and am going to see if it has ever had the recall done.

Meanwhile, went ahead and pulled the injectors out. Everything in the fuel rail and throttle bodies looked good. Letting the injectors soak for a few days, then am going to clean them with a fine needle and give it another try. Can't think what else is causing the issue. Already cleaned the airbox/air filter out before, so that's good to go.

Hoping this does the trick.

 

[Norbert]

cool thread :thumbup:

 

[04fizzer]

Checked the TPS through the diagnostic mode. Registered 15 when closed and 100 when open, which is right in the spec range (high end of them, but still within them). Pulled the VIN and am going to see if it has ever had the recall done.

Meanwhile, went ahead and pulled the injectors out. Everything in the fuel rail and throttle bodies looked good. Letting the injectors soak for a few days, then am going to clean them with a fine needle and give it another try. Can't think what else is causing the issue. Already cleaned the airbox/air filter out before, so that's good to go.

Hoping this does the trick.

Let them soak in the cleaner, and spray them out with compressed air or the cans of carb cleaner. It's possible there's enough buildup that it's causing a problem, but not enough to see, or where you can see it.

 

[miketherider]

Pulled the injectors out last night and hooked them up to an external battery and went to see if they work. They would barely spit and spatter at first, but now are flowing nicely. Went to put everything back together, and realized the rubber o-ring between the head and the injector was MIA for the #2 cylinder. So, stalled out once again. Luckily, a dealer 30 minutes away has them in stock. So, hopefully will put it back together by Thursday and have it running.

 

[TownsendsFJR1300]

That is excellent! Wish you had some pictures of cleaning them, I never had to service one before... Sounds like your about there!