I know there are other posts on this, but on my last three rides of my TE-630 with 3,000 miles I have had several instances of the fuel pump failing to operate. Loss of prime when turning on the bike Two happened at very low speeds, engine dies then fails to restart, have to wait about 10-15 minute during this time also lift off the tank and disconnect pressure line and electrical connection Three happened after shutting the bike off, on restart the pump again fails to prime, thus the no start issue. Again take of the tank and remove and reset things In all instances the bike does restart. I think the aftermarket pump may be the solution. Just a heads up to all Paul O
Make sure you go with the Hi Flo after market pump and not the cheap eBay one. However the HF is available on eBay too
Bump This happened to me on the weekend. The bike just stopped. There was no sound of the fuel pump priming when I switched it off and on. I checked the fuses, swore a bit, and called my darling to come with the trailer. As I took it off the trailer, I turned it on for the familiar sound of the fuel prime, and it started straight up! I checked all the wiring and connections, but could not find anything wrong. I am reluctant to just start replacing bits in the hope that might fix it, but a bike I can't trust not to stop in the middle of nowhere (it's preferred territory) is pretty useless. Any suggestions?
Interesting - this is almost identical to the issue I'm having with my 2010 TE450. I originally thought it was the spark plug as it had poor spark when I tested it. I have been through 3 plugs in 3 months. When describing the problem to a mechanic mate he said that would not explain the fuel pump not priming though - fair point. He reckons it could be a stator/generator issue - says that the wiring of the Husky is a horrible design. Given the issue makes the bike so unreliable I have parked it up for now. My mate has offered to go over all the wiring over Christmas to see if he can sort it out. If you guys figure out the problem before then I may be able to help him speed up the diagnosis. It's such a difficult problem as it seems to be intermittent in nature.
I added a small led above the cluster that's hooked to the pump power/ground so I can see if the pump has power to it. Also plumbed in a fuel pressure gauge. I keep one of the cheap ebay pumps in the tool kit. Figure with all that I'll never have a pump issue...
Remove the gastank. There is a white plastic connector in the wiring loom that corrodes and turns the inside of the connector plug green. Pull it apart and clean up the connections apply dielectric grease problem solved.
Backmarker Thanks for the insight.. Is the corrosion causing power disruptions? Suggestions for cleaning the connection? I was about to ask those that have experienced this if they have the JD Tuner also wired into their fuel metering system??
I have a JD. The connections looked clean and undisturbed, and the JD lights went through their normal start-up cycle. The fuel pump did not. ...and then it did.
Yes the corrosion is the problem. Water runs down the harness and collects in this plug. I dunked both ends of the plug in a mix of baking soda and water then sprayed with contact cleaner. A light brushing with a brass wire brush followed by dielectric grease. I also wraped the connecter with black tape on the top side so water could not re enter but left the bottom side open. Been fine for the last 5000 miles.
Is this the connector Just for clarity, Are you referring to the connector on the bottom of the fuel pump or another located under the fuel tank?
I did all of mine. As I remember there was only one white connector, its zip tied to the upper frame under the gastank area.
I checked all the contacts and they look clean. I gave then a squirt of electrical cleaner just in case. Yesterday, I took the risk to take it out again, and 45 minutes out, it stopped. I lifted the tank, and switched it off/on the fuel pump cycled through as normal. I dropped the tank back down ( this time leaving the bolts out) and rode on. The process was repeated 10 minutes later, and the 5 minutes after that. On the last time, as I switched the power on, the fuel pump spat the line out, spraying fuel a the hot headers! The line would click back in and sit nicely, but spit out whenever the pump started working. I held it in by jamming a lump of wood between the fuel line and the radiator, and rode home. An hour ride not missing a beat...
It seems that the standard fuel pump is prone to overheating and stopping. What I thought was me fiddling with connections was just giving the pump time to cool down. I put in a pump/filter rebuild kit and it is working fine. As to the line coming off, that is a separate problem. The jaws just don't seemed to hold anymore. So I expoyed it in place, and fitted a dry-break connector further down the line.
Hey I got a question. I have a 2012 txc250 and randomly now the relay doesn't kick when I hit the on button an if I let it sit for a minute it kicks and then the pump turns on. It's happened a few times in the trail also after shutting the bike off. So would it be the relay bad? Hooked up pump directly to battery and was fine. Any thoughts ?
The battery plays a major role in pump pressure/hot starting. I had serious hot start issues with my 511. It was the battery. Switched over to an Earthx and never had an issue again.
The battery is the original and I checked it and it's putting out the full charge so I don't think that's the problem. Maybe relay going bad?
