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fuel pump quit today and left me stranded... then started up again

Started by micah360, April 24, 2012, 05:48:53 PM

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Ok... here we go.... I went for a ride today and the FJ acted like it was running out of gas... started running rough then died (I coasted into a gas station).  I was about 40 miles into my ride and left home with a full tank of gas, so I know it wasn't out of gas.

When I turned the switch off, then back on, I couldn't hear the pump's pumping sounds at all.  

So here's the trouble shooting I did in the parking lot while it was stalled.
1. I switched the fuel switch from "on" to "reserve" with no change.
2. I pulled the fuel line off the fuel pump and gas was flowing, so I know the pump was getting gas.
3. I unplugged the fuel pump power and plugged that back in too.  No change.
4. I unplugged the sending wires from the gas tank and plugged them back in too (just cause).

After sitting (right panel and seat off) for about 20 minutes the pump switched back on and started making the pumping noises once again.  So I knew it was time to try and start her again... and then she starts up.  Rode great home too.

One thing I did notice was that the fuel pump was very hot to the touch.  This is why I left the panel off, to let it cool down.  So it seemed that when the pump cooled down, it started working again.

This is the second time this happened to me now.  I did no trouble shooting the first time as it was my 2nd day with my new (used) FJ, and wasn't really sure what to do.  But (like today), after letting it sit for about 20 minutes, it started back up again.  Weird thing though is I've been riding the bike as much as I can since I bought it, and it's only done this twice now, in about 300-400 miles.

What do you guys think... time for a new pump?  Would that be the first logical step in this process?  Or should I start with this point switch/repair kit?


If your going to go with the points set, Randy at RPM carries them. They are out of stock at the moment, but check with him as to when he will have them in. Price is comparable to the UK vendor and shipping will be less. You can find him in the Vendors forum.


"we often refuse to accept an idea merely because the tone of voice in which it has been expressed is unsympathetic to us."
~~~friederich nietzsche ~~~

Pat Conlon

Micah, you've seen this file, correct?

New oem FJ fuel pumps are prohibitively expensive ($338+)

You could spend money on new points which *might* work.... or you could shop FleaBay for a used R6 pump.

1) Free Owners Manual download:
2) Don't store your FJ with E10 fuel
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire:
Fuel line:


yes... I have seen the compatible pumps... I've been looking on ebay for used pump at a decent price.  I saw one a couple of weeks back at a good price (from a 2007 YZF 600), but didn't jump on it. 

I just wanted to check with other's on this forum to see if anybody else has had this issue with the pump so I didn't waste my money on a pump, and it ends up being a relay or some other electrical gremlin.

Quote from: Pat Conlon on April 25, 2012, 11:06:33 PM
Micah, you've seen this file, correct?

New oem FJ fuel pumps are prohibitively expensive ($338+)

You could spend money on new points which *might* work.... or you could shop FleaBay for a used R6 pump.


maybe I'll try the Napa pump... seems like the cheapest option.


I have the pump in stock and the fuel pump points. The points should be back in stock next week.

Randy - RPM
Randy - RPM


I'd pull the pump and check the points 1st, before buying parts that may or may not be needed.....  Are you sure the carbs weren't getting fuel?  There's been several instances of flakey kickstand switches, and even one I remember where the sidestand spring was weak and allowing the stand to sag far enough that bumps would cause it to kill the ignition...
Rich Baker - NRA Life, AZCDL, Trail Riders of S. AZ. , AMA Life, BRC, HEAT Dirt Riders, SAMA....
Tennessee Squire
90 FJ1200, 03 WR450F ;8^P


It acted like it was running out of gas. It just didn't die, like when the key is turned off. It surged and sputtered (for about 15 sec), then finally died.


I'm not sure if I'm right on this suggestion! What if you bypassed the pump and connected the carbs to the tank line direct? Isn't it the case that the carbs only need to be fed by the pump when the fuel taNK IS LOW? If you keep the tank topped up and it runs OK, this might prove that the pump is at fault?

I should add that i hasve had a bottle of wine, and might be talking bollacks :crazy:
BMW 1150GS
Moto Guzzi California 3


When my fuel pump died, I did bypass it with a spare bit of hose.  This worked as long as the speed was under about 90kph (55mph) and the tank was more than half full.  I wouldn't want to ride this way other than as an emergency fix to get me home so I could order a new pump OR to a shop where I could buy a new fuel pump.
As this happened at the start of a planned 3 day trip, I was able to get to a REPCO (RipEveryPoorCuntOff) shop that had a suitable low pressure pump that would fit.  I over-paid for it, but at least I was able to keep to my trip.



I picked up an Airtex E8016S pump and got it installed yesterday.  Just had to re-route the 'in' fuel line a tad and had to buy 1/4" hose fittings (instead of the 5/16" fittings that came with the pump).  I reused the stock pump mount and it all fits perfect. I also ditched the little filter that came with the pump, as I have an inline filter right before it anyways (plus I don't think it would have fit in the spot with the supplied filter on it too).

I took it for a 15 minute ride and the new pump worked perfect... but time will tell I guess as the problem I was having was intermittent anyways.  Also... the pump's sound is way quieter than the stock pump, you can hardly hear it pumping when you switch the key on.  That stock pump was pretty loud (unless that was just one of the traits of my pump failing).


Well... I have about 150 miles under the new pump... so far so good.