'10 TE250 fuel pumpo failure

[R_Little]

Cruising and finally digging my new bike at the Beehive I rode through a bony section jumped a log and the bike sputtered and stalled. Cranked it and it woud not restart. I noticed the fuel pump was not cycling.

Checked all the fuses and relays wires etc and it all looked good. Turn the key and heard the relay cycling but no pump.

Take pump out of tank trailside in the sticks weeds and leaves and connect it to the plug...pump works now. Put it back. Bike runs fine again. Get to check out 45 min late but did not hour out.

Last section of the day, same thing hit some whoops bike stalls no fuel pump. take it out again hook it up pump won't run. wiggle wires still no run. Wiggle large 2 wire white connector, pump runs. put it back in tank...spill gas all over myself when pump was not seated into tank...take it out again in the weeds and leaves and sticker bushes. replace. Ride to check out 50 minutes late. shut bike at KC at end and the bike does not restart. get my sexy $8k italian stallian towed in by 1990 DR350. Bike starts at truck.....go figure.

What do I do now?

The bike has 300 miles on it because it would barely run before the re-flash. Now it runs fine but I am not going to race it again out of DNF fear. I'm competing for season points this year.

I hope I do not have to buy a $500 fuel pump for my new $8k bike.

Any suggestions?

 

[waserman]

fuel pump?

Try checking out the things that I tried in this link.I believe that the temperature sensor was to blame but I tried severasl other things as well. http://www.cafehusky.com/forums/showthread.php?t=12070

 

[AndrewS]

Shouldn't the problem (whatever the cause may be) be a warranty issue?

 

[R_Little]

Shouldn't the problem (whatever the cause may be) be a warranty issue?

dunno,

I told the dealer. Bike was bought in Feb. 300 miles on it.

 

[R_Little]

Try checking out the things that I tried in this link.I believe that the temperature sensor was to blame but I tried severasl other things as well. http://www.cafehusky.com/forums/showthread.php?t=12070

My problem is no pump at start up.

The pump stops bike runs out of gas pops stalls and dies.

Starts after fidgiting or maybe after sitting for 30 minutes.

pump was not hot when I removed it and the tank wasr at least 1/2 full each time.

The tank was never run dry.

 

[Darkside]

Sounds like an electrical connection problem. The fact that the pump was hot when removed sounds alarming though. I wonder if there is an overheat shutoff relay.

 

[JasonfromMN]

One of those problems the dealer cant find unless they ride it, which they wont. Hard to get that covered. A riding buddy(07WR250F as main scoot) just bought a DR350 and likes it. Cool bike.

 

[R_Little]

Sounds like an electrical connection problem. The fact that the pump was hot when removed sounds alarming though. I wonder if there is an overheat shutoff relay.

The pump was NOT hot when I took it out.

 

[R_Little]

One of those problems the dealer cant find unless they ride it, which they wont. Hard to get that covered. A riding buddy(07WR250F as main scoot) just bought a DR350 and likes it. Cool bike.

Understand, but this is a street legal bike that the engine just cuts out...not a good thing.

Certainly they will understand that I'm not swapping fuel pumps for the heck of it!

I paid almost MSRP for it.

 

[R_Little]

Update.....

I need to haul it back to Town and Country to have them look at it.

Problem is, it is running fine now.

I may check again and see if I can isolate it to that one connector that seemed to fix it in the woods. It did not look however like that connector came apart in the woods. I'll report.

Got to get the 125 motor back together tonite!

No more points racing for me after this season.

Way too much aggravation.

 

[stushusky]

I had a similar problem with my 300kms old TE450 2010. It ran like it had a clogged main jet - would start ok but then die when you gave it some gas. Had to limp it back to the truck for 20km but it would cut out often. Same thing, pump not priming, worryingly when I opened the gas cap there was a lot of vapour in there - looked like smoke!!
After I removed the pump I found the black wire on the pump to be loose. Re crimped the connector and put it back on. Could it of been smoke from a sparking bad connection? Just not enough air in the tank to ignight, I hope not!

 

[R_Little]

I had a similar problem with my 300kms old TE450 2010. It ran like it had a clogged main jet - would start ok but then die when you gave it some gas. Had to limp it back to the truck for 20km but it would cut out often. Same thing, pump not priming, worryingly when I opened the gas cap there was a lot of vapour in there - looked like smoke!!
After I removed the pump I found the black wire on the pump to be loose. Re crimped the connector and put it back on. Could it of been smoke from a sparking bad connection? Just not enough air in the tank to ignight, I hope not!

Mine is not like that....the pump just stops, period.

Take it out move stuff around and it works. Bike runs fine when pump is running.

The problem is the fuel pump is the most critical malfunction on a bike. Everything else you can ride out on...a flat...a bent rotor....a bad crank bearing... a siezure...even a hole in the engine can be plugged for a while.

A bad fuel pump means dead bike.

 

[jmetteer]

A bad fuel pump means dead bike.

This has been my biggest hangup on going to an FI offroad bike.

It is not isolated to Husky either, my friend just had the pump fail on his 09 Honda CRF450. Not a huge deal at the MX track, unless you are on the face of a 90' triple...

Later,

 

[brock]

Warranty!
If the bike is within the period get it changed for a new one.
I did and I don't have any restart after stall problems now either!
The new pump has a big rubber cowl around it too, not sure what it does but they obviously felt the need to add it...

 

[HUSKYnXJnWI]

Sounds like you have it narrowed down to loose pump wires/connector issues. If that's the case its not exactly a bad pump itself- but also sounds like you aren't 100% confident in the problem yet.
That being the case- It might be worth checking electrical issues such as the coil connections- my bike's coil connections (grounds to frame) were loose at one point and the bike ran intermitantly- it was terrible, I was with a buddy on a trip to a trail system 6 hours away. My bike would die in the middle of every hill and in every bad circumstance available. At the time I blamed the heat, the efi, and the devil himself. After the trip- I thought to check the coil connections and found them slightly loose. after cleaning them and lock-tite-ing them I could not replicate the problem. I belive FTG had loose coil connections at one point on his 2008 and had thought he had a pump failure prior as well.
might be worth a shot to check...

good luck either way

 

[R_Little]

Sounds like you have it narrowed down to loose pump wires/connector issues. If that's the case its not exactly a bad pump itself- but also sounds like you aren't 100% confident in the problem yet.
That being the case- It might be worth checking electrical issues such as the coil connections- my bike's coil connections (grounds to frame) were loose at one point and the bike ran intermitantly- it was terrible, I was with a buddy on a trip to a trail system 6 hours away. My bike would die in the middle of every hill and in every bad circumstance available. At the time I blamed the heat, the efi, and the devil himself. After the trip- I thought to check the coil connections and found them slightly loose. after cleaning them and lock-tite-ing them I could not replicate the problem. I belive FTG had loose coil connections at one point on his 2008 and had thought he had a pump failure prior as well.
might be worth a shot to check...

good luck either way

After I get my 125 back together for the next race I'll check that and all the other wires.

I really do suspect that it is that big white connector on the pump.

That was the last set of wires I wiggled before it restarted.

I'll check the connection across the connector with a VOM before I haul it all day back to the dealer.

 

[Up-tite]

Just for grins I would pull any pump that had the zip tie come loose and retighten the connections. Reason when the zip tie comes loose or off the wire connections and bag filter are the only thing holding it down or in this movement does and will loosen the connections just a PM thought.
Later George

 

[R_Little]

Just for grins I would pull any pump that had the zip tie come loose and retighten the connections. Reason when the zip tie comes loose or off the wire connections and bag filter are the only thing holding it down or in this movement does and will loosen the connections just a PM thought.
Later George

Took it out in the driveway last nite.

The pump is not loose. I played with the white connector and could not get it to stop running but I only ran it for a second or two since it was out of the bike. The other wires are tight and the meter says the connection on the plug is good.

The pump is running right now. I did notice that gas continued to drip out of the pump outlet when I removed the tank. It did not do that when I took it off to replace the CDI last month.

I know for certian that I had to remove the pump from the tank and play with the wires in the field to get it to run....took 30 minutes R&R the pump in the woods.

The relay was clicking and the pump was not starting. Playing with the connectors outside did nothing.

Each time it did it about 7 miles into a 8 mile section after hitting somethng like a log or big whoop on the trail.

It poped after a good hit, ran out of gas then no fuel pump until I took it out.

I'm riding my 125 at Michaux this Sunday.

 

[CARL REHATCHEK]

Rich,

Question ??? When the bike stopped running and you disconnect the fuel line was it from the bottom at the throttle body or way it from the top at the tank...

Reason being if it was at the bottom then fuel should always come out til the line is drained that is one way to see if the fuel stopped of if it was something else electrical..

Mind you that is only going to run out if the fuel pump engergizes to pump fuel

Just a thought

Chow, Carl

 

[proeasy]

On a ride in the UP (Michigan) this summer we had a FI 610 fuel pump do the same. Found wires behind the headlight had worn through and were grounding against the headset (I think that is what it is called)

Taped and covered them and bike ran fine.

On the same trip last summer my FI 510 did the same in a rain storm, but never found the root cause. Dealer said it was a loose connector.

PRO