Fuel Pump replacement

bikerbob5864 · November 20, 2018, 23:08:36 PM

Yea, I do this when I have to......They do it everyday so you would think they would get a little further than presenting me the bill. I think I'm going to throw an ECM at it and see what happens(so much for leaving it alone till spring). I can Wget a used one for about half the cost of a new one, plug it in and see what it does. If it works, great, if not..... I'll re-sell it. It hasn't had any fuel controllers hooked up to it, all bone stock......................................................so we'll see what happens

greenbarn · November 19, 2018, 21:06:07 PM

Doesn't say much for the shop that they couldn't find this problem in 3 hours.....

bikerbob5864 · November 18, 2018, 22:46:51 PM

I think I'm going to take a break from it until Spring when I can work on it outside. I can get a used ECM for about 1/2 price, which is still about 300.00. My last trip to the shop cost 300.00 just for 3hrs of diagnosis with no results. Sure wish I had a place to work inside where it's warm. I could've spent some time this last Summer, but.....there was too much good riding to be had. I just hope my 1600 Nomad or Softail don't take a dive.

greenbarn · November 18, 2018, 12:15:00 PM

Sorry you're having so much trouble with it... keep us posted.

bikerbob5864 · November 17, 2018, 19:22:57 PM

Okay, can't bench test the ECM away from the bike/Harness so............it's haul it to the nearest Kawi dealership in Rochester, MN. about 75 miles away. Man! I hate this crap! I talked to them and they seem at a loss also, but will be willing to look at it. Oh well, it's only money!!!!!!!

bikerbob5864 · November 09, 2018, 15:08:53 PM

Here's the latest diagnosis of the no start condition/Tested pump pressure and regulator, both were within spec........Pulled injectors, tested same-spray pattern good, Tested continuity to injectors.....NONE.............disconnected fuel controller, continuity to injectors restored. Still no fire. Will be taking ECM to Kawasaki Dealer to be bench tested. Any other adivice?

Bob

bikerbob5864 · November 07, 2018, 11:33:30 AM

Okay, thanks for all the help and advice. I'll strike out in that direction and check for injector pulses. I DON'T have any Mitsubishi Noid lights, or at least they aren't labled as such. I guess I'll just test each one and see if any fit and work.
Thanks again. I'll let you all know what I come up with

Bob

Troll · November 07, 2018, 07:35:55 AM

You don't need to have the tank on to test for injection pulses. They are a separate circuit and have nothing to do with the fuel pump. The injectors are mitsubishi, if that helps.

bikerbob5864 · November 06, 2018, 20:20:33 PM

It DOES have a Cobra 2000FI Fuel controller. I did not install this, came on the bike.
I DID disconnect the Fuel Controller and ran thru the whole start/run sequence again......with the same results. I DO have some Noid lights for checking impulses, but I can't be sure if mine will fit as they are for Automotive use(Bosch and the like).
So, I have to leave the tank on the bike, prop it up to gain clearance, and find a Noid that works in an injector without damaging it......correct?

greenbarn · November 06, 2018, 19:57:27 PM

Quote from: bikerbob5864 on November 06, 2018, 16:58:49 PM
Okay, since I don't have a pressure testing setup, I took it to a shop..............not a Kawasaki shop but the closest to me that handles fuel injected Japanese bikes. They could not find anything, and said they thought it was the ECM. I doubt that since the bike WILL run on an outside fuel source, and will continue to run until the fuel source is taken away.

Not necessarily... the ECM does many things at the same time... enables fuel pump. enables fuel injection pulses. enables ignition (spark). It's possible (I don't know enough about this ECM to know for sure if these are all independent) .

So like Troll is saying- before you condemn the fuel pump, really need to make sure it's getting injector pulse. Also like he said- I've seen (or heard of) at least 2 bikes that wouldn't start because of a bad power commander. Don't know for sure but stands to reason the PC problem would be related to injector pulses.

Troll · November 06, 2018, 19:42:31 PM

Injection pulses...does this thing have a power commander or something like that installed?

bikerbob5864 · November 06, 2018, 16:58:49 PM

Okay, since I don't have a pressure testing setup, I took it to a shop..............not a Kawasaki shop but the closest to me that handles fuel injected Japanese bikes. They could not find anything, and said they thought it was the ECM. I doubt that since the bike WILL run on an outside fuel source, and will continue to run until the fuel source is taken away.

Troll · November 06, 2018, 16:43:00 PM

If the pump runs to prime the system, then the next step is finding out if you have sufficient pressure, and then if you have injection pulses. The system will normally pressurize to about 40# at key on.

bikerbob5864 · November 06, 2018, 15:35:06 PM

It is a 2002 1500, no it will not keep running, yes I can hear the fuel pump energize for at least 2-3 seconds when I turn the Ney on
No, I did not check the voltage at the ECM. I DID talk to a 16 year Kawasaki Mechanic at a nearby dealership and he seems to think it is the fuel pump also. He asked if I could hear it running while cranking the engine and I said I could not. Do you have any other suggestions?

Troll · November 06, 2018, 07:53:16 AM

Quote from: bikerbob5864 on November 05, 2018, 20:22:12 PM
I would like to add to my situation something that I did not find in any of the other posts regarding this issue. My bike WILL start with Ether or an outside fuel source, which to my way of thinking discounts the idea that it is an electrical/fuse/relay/ECM problem. 3 things must be present for an engine to run, AIR-FUEL-VOLTAGE. Since I provided the fuel outside of that triad loop, my obvious direction is a fuel delivery problem. I was just looking for someone who might have used an aftermarket pump and what type of experience they had.

So it starts...does it keep running? Do you hear the fuel pump run for 2 seconds when you turn the key on? What year is it? Did you check for battery voltage at the fuel pump connector? One side of the plug is B+ with the switch on, the other side goes to the ECM for a switched ground. If you ground the connector lead going to the ECM, does the pump run?

bikerbob5864 · November 05, 2018, 20:22:12 PM

I would like to add to my situation something that I did not find in any of the other posts regarding this issue. My bike WILL start with Ether or an outside fuel source, which to my way of thinking discounts the idea that it is an electrical/fuse/relay/ECM problem. 3 things must be present for an engine to run, AIR-FUEL-VOLTAGE. Since I provided the fuel outside of that triad loop, my obvious direction is a fuel delivery problem. I was just looking for someone who might have used an aftermarket pump and what type of experience they had.

chief · November 05, 2018, 17:01:42 PM

Anyone who has done this, we'd appreciate a write-up. I'll format it and post it in the mods area.

Pilgrim · November 05, 2018, 14:41:04 PM

I know some on here have had a good replacement with the Quatum Fuel Systems pumps. Search fuel pumps for their posts...in the search box.

bikerbob5864 · November 05, 2018, 12:07:25 PM

Thanks for the reply, I see several aftermarket kits available, so I'm assuming it is possible and at considerably less cost than the single unit, but we all know what assume can mean. Well, a kit is 30 bucks so if I spend that first and win.........great..............if not a win...........then I guess I chalk it up to learning.

chief · November 05, 2018, 09:01:02 AM

I haven't... but the fuel pump and plate are an assembly... one part number. Sorry can't be more help.

bikerbob5864 · November 04, 2018, 22:28:19 PM

Has anyone ever replaced a fuel pump as an individual part instead of the whole tank base plate unit, and if so what problems if any did you encounter?