91 Fuel Pump Relay Location?

[Easterntide]

Did some low quality searching but didn't find what i think i need.

Went to start the FJ yesteday after its winter hibernation. Had fully charged battery, kill switch was set to ON, however no fuel pump activation sound after 5 seconds. Tried several times.
All fuses were solid and not blown.

I'm incompetent w a multimeter however the fuel pump connector (on the battery side yes) was showing no data when i connected the meter. i disconnected other connectors and they showed varying power levels.

i don't have a spare fuel pump to try but my local mechanic mentioned it could be the relay.

Can someone tell me where that is on the bike?
Option one is to tap on the fuel pump itself he said, option 2 is to take off the pump and check the switch.
but if its not getting power to it from the battery side...is that the relay?
is it possible to wire the pump directly from the battery to see if its working?

Was working fine prior to winter put away.

thanks for hopefully not hammering me too hard on a likely obvious thing...

Don

[FJmonkey]

I am new to FP FJ's but I know that you can disconnect the FP and jump it direct to the battery with a few wires. If it actuates then you need to look further up stream. My Clymer's book shows a FP relay, so that will be the next place to look if the FP does fire off when direct to battery.

[ribbert]

Did some low quality searching but didn't find what i think i need.

Went to start the FJ yesteday after its winter hibernation. Had fully charged battery, kill switch was set to ON, however no fuel pump activation sound after 5 seconds. Tried several times.
All fuses were solid and not blown.

I'm incompetent w a multimeter however the fuel pump connector (on the battery side yes) was showing no data when i connected the meter. i disconnected other connectors and they showed varying power levels.

i don't have a spare fuel pump to try but my local mechanic mentioned it could be the relay.

Can someone tell me where that is on the bike?


Option one is to tap on the fuel pump itself he said, option 2 is to take off the pump and check the switch.
but if its not getting power to it from the battery side...is that the relay?
is it possible to wire the pump directly from the battery to see if its working?

Was working fine prior to winter put away.

thanks for hopefully not hammering me too hard on a likely obvious thing...

Don

Don't forget, the pump only gets power when the ignition is turned on for a few seconds unless the motor starts.
So, if you leave the ignition on and start tracing power, there will be none to the fuel pump after a few seconds, unless the engine fires.

Hook your test light or multi meter up to the power side of the fuel pump before you turn the ignition on, then see if there is power as soon as the key it turned.

It is not unusual for the pumps to need and encouraging tap after a layoff.

My bike is still on its original pump at 130k but does need a couple of raps with something metallic to spring it into life if unused for any length of time. It has been like this for years but never let me down. I do carry a $25 spare on the bike though for the day when it finally does die because this never happens anywhere convenient.

If it was fine when you parked it, it is highly unlikely you have a problem with power supply. It is more likely forgetting that power is only supplied for a short time after the key is turned on if the engine does not start up.

Also, the points in the pump have most likely never been cleaned, they are not part of scheduled servicing and no one ever does them. A 5 min job with a bit of fine emery or sandpaper or points files etc.

Give it a few taps with something metallic immediately after turning the key on and see how you go.

All this assumes you have healthy voltage at the pump, they don't like it if the voltage at rest is a bit down.

Get back to us if this doesn't do the trick.

Noel

[Easterntide]

thanks Noel. I'll do some checking on that tonight.
so when hunting for a spare pump...any recommendations?

[Easterntide]

Happy days: hit the pump a few times...thoughT I heard a sound but didn't make the normal pump sound. Went to work and after coming home I checked the local cost of a pump. 335$ cdn. Oi. Fortunately my shop didn't have any stock.
Came home and tired it again and it immediately fired over!!
Sprung to life and I became super happy :-)

Of course my clutch plates has stuck together and after a few stomps into gear and stalling they eventually freed up and finally I think it's ready for its first ride.
Snowbanks are still 6 to 8' so it may be a few weeks :-(

Thanks for the input as always an awesome forum.

Don

[movenon]

Happy days: hit the pump a few times...thoughT I heard a sound but didn't make the normal pump sound. Went to work and after coming home I checked the local cost of a pump. 335$ cdn. Oi. Fortunately my shop didn't have any stock.
Came home and tired it again and it immediately fired over!!
Sprung to life and I became super happy :-)

Of course my clutch plates has stuck together and after a few stomps into gear and stalling they eventually freed up and finally I think it's ready for its first ride.
Snowbanks are still 6 to 8' so it may be a few weeks :-(

Thanks for the input as always an awesome forum.

Don

IMO don't buy a stock New Yamaha pump.  Go to e bay and shop around.  Ones that will work range from 30 to 100.00. Big selection. Also the points might be the only problem. If so try cleaning them. They are also available. Randy at RPM also has some I believe.
In an emergency you can hook a fuel hose from your petcock down to the carb input bypassing your filter and pump. It will get you home just fine..
George

[novaraptor]

If no luck with RPM, then Moto Part Hub in Illinois, US, part 18-4615. $25.20 US. Ahh, here it is:
http://www.motoparthub.com/18_4615_K_L_Supply_Universal_Fuel_Pump_Point_Switch_Kit
Just did this last month... No relation or affiliation with the business..

[Easterntide]

pump crapped out again. so out i go and buy one on eBay. it arrives. the fuel in/out port holes are bigger than the factory ones. ok fine, so i stretch them a bit and eventually get it all mounted up and the bike fires over again. Happy day.
and then i come back from a 20 min ride and park it.

and thats when the puddle of fuel starts to happen.

i figured for sure it was my mounting/stretched tubes. but nope.
the fuel was leaking out where the 2 parts of the fuel pump are joined.

feck.
so now i'll steal its electronics and remount it to my old pump and cross my fingers.

[Easterntide]

alright...well i switched the relays and now i get this when turning the bike on.

http://www.youtube.com/watch?v=http://www.youtube.com/watch?v=$1#errorNo longer available

ticking.
what does the ticking mean?!

i'm about to drop 100$ for an R6 fuel pump at a local junk yard, optionally its 350 from yamaha direct.
i know RPM has them but its 2 weeks shipping for me for that and its already been 2 weeks while i waited for the crap part i bought off ebay for 30$.

Don

[FJmonkey]

Don, with the video not working we cannot tell what the ticking is. However, when you turn the key and power up the bike you should hear the fuel pump ticking (pumping up to pressure) for about 3 to 5 seconds. It stops until the engine is running but you can't hear the pump over the engine noise.

[Arnie]

Be very careful of the R6 fuel pump.  If the R6 it came from had fuel injection, it will be a HIGH pressure pump, not the 3-5psi pump the FJ needs.  The increased pressure will certainly blow right by the needle valves in the FJ carbs.

[Steve_in_Florida]

Did I miss something, or was the original question never answered?

I'm working to get my recently acquired `92 ABS bike back on the road. Forks, headlight, fairing bracket and fairing all replaced. Fuel pump won't click. Tested the pump on another bike, and it works.

Wiring harness on a `92 non-ABS bike has the fuel pump relay located near the fuse box under the seat. I'm not finding it on the `92 ABS bike.



The only other relays I'm finding are up front, under the fairing on the right-hand side, and the CDI box on the left-hand side.

Clymer manual wiring schematics only confuse the issue.

Does anyone have a definitive answer?

Steve

[jscgdunn]

Since you are in Canada, here is an option that works very well and is readily available:
http://www.princessauto.com/en/detail/12v-electric-fuel-pump-solid-state-cube/A-p8606253e


Jeff

[jscgdunn]

Since you are in Canada, here is an option that works very well and is readily available:
http://www.princessauto.com/en/detail/12v-electric-fuel-pump-solid-state-cube/A-p8606253e


Jeff

Be sure you get the 40171 pump...they can order it.  The off the shelf pump 40109 may have too high pressure output.

Jeff

[Steve_in_Florida]

I was finally able to figure this out for myself.

The fuel pump relay on ABS bikes is under the front fairing, on the right side, and is component of the front wiring harness assembly.

The fuel pump relay on non-ABS bikes is under the seat, on the right side, ans is a component of the rear wiring harness assembly.

If you swap the front fairing bracket (with the attached wiring harness) from a non-ABS bike to an ABS bike, then you'll wind up scratching your head in wonder, looking for the fuel pump relay.

Doh!

Once I laid out all the parts from all the bikes, the solution became clear: the front wiring harness is NOT interchangeable between ABS and non-ABS bikes.

Lesson learned!

I have swapped the front harness back to where it belonged, and all is well with the universe again.

As a result, I have been able to get both of the `92's that I acquired back in 2015 running again. The one I found in Virginia Beach is now tagged, and I took her for a spin around town yesterday. The one I got from Dean now starts and runs, but I have to sort out some other bits before she'll move under her own power. (Mount the exhaust cans, side panels, rear brake, bleed front brake and clutch, etc.)

Some projects take longer than others, but there is progress being made!

Thanks for reading...

Steve

Did I miss something, or was the original question never answered?

I'm working to get my recently acquired `92 ABS bike back on the road. Forks, headlight, fairing bracket and fairing all replaced. Fuel pump won't click. Tested the pump on another bike, and it works.

Wiring harness on a `92 non-ABS bike has the fuel pump relay located near the fuse box under the seat. I'm not finding it on the `92 ABS bike.



The only other relays I'm finding are up front, under the fairing on the right-hand side, and the CDI box on the left-hand side.

Clymer manual wiring schematics only confuse the issue.

Does anyone have a definitive answer?

Steve