1992 FJ1200 - Cranks but no ignition + fuel pump relay location

[FJHero]

Hi everyone, I'm a fairly new 1992 FJ1200 owner and am glad to be a part of this community!

The bike was running beautifully but I'm having an issue now where the bike cranks but there's no ignition - I'm suspecting the fuel pump relay as the pump's clicking seems weak after the first failed start and I'm only finding 11V or less at the connector to the fuel pump, with the battery freshly charged with good voltage.

I'm weirdly unable to find the fuel pump relay on the bike, I'm under the impression that this should be near the fuel pump and accessible behind the right side panel? The blue/black wire from the fuel pump connector appears to go into the wiring harness, and reappears to go into the fuse box under the seat. Would someone mind confirming if I'm just looking in the wrong place for the fuel pump relay, or have a photo of where the relay should be?

Here's what happens when I attempt to start:
-battery fully charged, voltage checked at fuel pump connector 11V, turn the key and hear the fuel pump clicking for 5 seconds
-hold start, engine cranks as long as I'm holding it but there's no ignition
-turn the key off and on again, voltage at fuel pump connector <11V and fuel pump clicks maybe twice
-same crank but no ignition condition

I'd appreciate any help, apologies for this post if it's redundant but I've attempted searching the forums for the relay location.

Cheers!

[86FJNJ]

how long ago was the bike running beautifully?

[FJHero]

It was running perfectly five days ago, then it was parked till yesterday when I attempted to start it and found no ignition.

[Pat Conlon]

My first thought...battery. But if the starter motor continues to turn over the engine without slowing down... then rule that out.

I'm going by memory but if I remember correctly, the fuel pump does not have a stand alone control relay (like the starter)
The control on the power for the fuel pump runs through the ignition box which also regulates the 5 second delay.
It's doubtful that went bad....what can go bad is the fuel pump itself.

Next: Rule out bad fuel pump. The contacts in the pump can be going bad and/or leaking diaphragm.

All Fuel pump FJer's should know that if they are out on the road and their fuel pump goes bad... (fuel starvation, e.g. running out of gas with plenty in the tank) they can bypass the fuel pump to get home.

All fuel pump FJer's should keep a male/male fuel line connector in their tool kit like this



Pull the seat and right side cover. Disconnect the inlet and outlet fuel lines from the fuel pump and with the line connector, connect the two lines together. I use a rubber shod small needle nose vice grip to pinch off the fuel line coming from the tank, that way I don't have to dick around with that fragile petcock.  I release the pinch clamp when the line connection is secure.

See if that gets gas to the carbs...it should....unless that's not your problem.

[rant on] If you do need a new fuel pump, DO NOT buy the eBay Chinese pumps. Buy oem Yamaha, Ask me how I know. [rant off]


Next step is to check the ignition.
Take a spark plug out and see if you have spark.

Let us know what you find.

[Millietant]

First you need to be sure if its a spark or fuel problem.

Pop out a plug and check to make sure you have a spark first, then check that you have fuel coming out of the fuel pump (pull the outlet pipe off and connect a short length of pipe to take the fuel to a can/jar) when you switch on and try to start the bike.

Once you've don this, you'll have ruled out a couple of possibilities, or confirmed your suspicions. Then it's a process of elimination to find out why the pump is not pumping.