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

[giantkiller]

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.

Yah Pat.I got a brand new ebay Chinese copy feul pump. With the 92 I just picked up. The stock one gave up. So I put the brand new copy on. It lasted about 50 maybe 60 miles.

[Pat Conlon]

Dont tell me it really is in the ignitor   

I just got back and tested continuity on the pump itself and it rang out good, then i checked for voltage from the connector with the bike running and then continuity and got no voltage and open line of course!

Good that you checked the fuel pump power with the bike running. I made the mistake checking the 12v power for the fuel pump with the key on....but the engine off.
I forgot about the 5 second power off function when there is no rpm signal to the ignition box.
Of course I had no power. I turned the key on, then casually walked around the bike and connected my multi tester, by then the 5 seconds had elapsed, thus no power. A rookie mistake.

You can look for another ignition box or like 86FJNJ did, install an aftermarket fuel pump safety switch and power your pump off your green plug, or other switched power plug.
This will bypass your ignition box.

I'm glad you got home!   Cheers. Pat

[Pat Conlon]

Yah Pat.I got a brand new ebay Chinese copy feul pump. With the 92 I just picked up. The stock one gave up. So I put the brand new copy on. It lasted about 50 maybe 60 miles.

If you open up the Chinese pump and look at those cheap stamped points vs the quality of the Japanese pump, the difference is striking.
Oh but they have a "lifetime warranty" If you even do manage to reach them (good luck) they will just send you another cheap pump.

Thanks again to RPM Robert for bringing me out a real pump to the WCR in Coleville. The RPM pump is still running fine.
Lesson learned.