My Fuel Pump Crapped Out in South Dakota!!!

[Zwartie]

Looking for some help here. As some of you know, I'm on the first leg of a 4-week ride to Alaska (and back) from Ontario. Was riding with my cousin (on his 1050 Tiger) when the fuel pump on my '92 FJ died - just outside Winner, SD. Had to MacGyver it by bypassing the fuel pump and connecting the lines using part of the end of a ball-point pen, electrical tape and duct tape:


Rode back into town and installed a fuel valve that I got at a local bike shop.


So we continued on the ride and for the most part the FJ was running fine except for a few times when we were riding on the open plains at 70 mph with a bit of a cross-wind and the bike began to sputter. Tried popping the gas cap with the spare key while riding and it did not seem to make any considerable difference. I've sent a PM to Randy for advice and may be ordering a replacement fuel pump to get shipped to my sister's place in Surrey, BC - we should be there by Friday. So I am wondering if anyone has advice on the sputtering - other than getting a new fuel pump, of course. I'm wondering why they put a fuel pump on the later FJs anyway as my '86 did not have one and ran just fine. What I am going to do tomorrow morning before we leave the KOA near Mount Rushmore is to remove the fuel filter and extra line that ends up making a loop down from the tank and back up to the carbs - going to try to eliminate anything that may restrict fuel flow. Another thing I noticed is that the bike seems to be getting considerably better mileage which likely means it's running leaner than with the fuel pump.

Your support is greatly appreciated!

Zwartie.

[Firehawk068]

I am sure you are running the bowls dry under load.................The carbs have different inlet needle/seat assemblies on the fuel pump equipped bikes.
There were also 2 fuel inlets on the gravity feed bikes. Yours has only one.
You can limp one along on gravity feed, but they don't like to run very well without the fuel pump...........I'm certain this is why she starts to sputter on you as the speeds climb.....

I have a friend who has a Hyosung 650 (one of the biggest POS bikes out there) and I have ridden it on a couple occasions.........It will get up to around 95mph, where it runs the carbs out of fuel, and the engine dies..............it coasts for about 10 seconds or so before the engine will re-fire and you can continue on your way..............

[movenon]

Sorry about the problem. I am in Meridian, Idaho. If you come through I can lone you my pump as my bike is down for some cosmetic repair....  

If the pump is electrically failing you might pull the end of the pump off and check out the points, its a  shot in the dark but if it is the points you might be able to clean it and get it running again for a short time.

Also IF NAPA or CarQuest has one a AIRTEX E 8016 S might work.

George

[jamesearthdrum]

When this happened to me on my way down to San Diego last year after the WCR, I shortend the fuel hose so it was almost straight going into the carbs. I was running 80+ the rest of the trip with no issues. You could pick up a piece of fuel line at an auto place to use so you don't have to cut your OEM hoses.

james

[Arnie]

Zwartie,

If you can find an auto parts outlet all the pumps below will work.
Or, just look for a low pressure (2-5 psi) 12V solenoid pump.
Its not rocket science.  Also, try to keep the tank 1/2 full or more.

Arnie

FUEL PUMPs
  BRAND     Part No      Pressure Range   Max. Flow
      FED-40104    1.5 – 3.5psi   28 gph
  FEDTRO      FED-40105    2.5 – 4.5psi   30 gph
   Sold on Ebay.au by       the_auction_broker  (Philip Island)
* FuelFlo        015        1  -  4psi   23 gph  1.5Lpm   
   Repco supplied for A$110.00
Airtex -       ES8016S      2.5-4.5 PSI   30 GPH
5/16" hose barbs   It is a solenoid pump that stops fuel if no power

[movenon]

Zwartie,

If you can find an auto parts outlet all the pumps below will work.
Or, just look for a low pressure (2-5 psi) 12V solenoid pump.
Its not rocket science.  Also, try to keep the tank 1/2 full or more.

Arnie

FUEL PUMPs
 BRAND     Part No      Pressure Range   Max. Flow
      FED-40104    1.5 – 3.5psi   28 gph
 FEDTRO      FED-40105    2.5 – 4.5psi   30 gph
   Sold on Ebay.au by       the_auction_broker  (Philip Island)
* FuelFlo        015        1  -  4psi   23 gph  1.5Lpm   
   Repco supplied for A$110.00
Airtex -       ES8016S      2.5-4.5 PSI   30 GPH
5/16" hose barbs   It is a solenoid pump that stops fuel if no power

Also a Faucet 40171 , requires a bit of adapting. has fuel shut off and reverse flow valve.

Also as James noted, I carry a 2' section of fuel line, 2 clamps, brass barbed splice and "official FJ" broken section of a pencil (to plug the fuel line, when removing the tank) coiled up in a zip lock bag in the tail section just in case.

George

[RichBaker]

Also as James noted, I carry a 2' section of fuel line, 2 clamps, brass barbed splice and "official FJ" broken section of a pencil (to plug the fuel line, when removing the tank) coiled up in a zip lock bag in the tail section just in case.

George

An 8mm wrench works a LOT better. That's what the stock petcock requires to turn it..... Lift the back of the tank, turn the square end and voila.... No leaking fuel.   

[movenon]

Also as James noted, I carry a 2' section of fuel line, 2 clamps, brass barbed splice and "official FJ" broken section of a pencil (to plug the fuel line, when removing the tank) coiled up in a zip lock bag in the tail section just in case.

George

An 8mm wrench works a LOT better. That's what the stock petcock requires to turn it..... Lift the back of the tank, turn the square end and voila.... No leaking fuel.   

That will work to    Seems lately I have to remove the tank and sit it aside so I have gotten use to just plugging the line. With my luck if I twist on the valve it will leak.............    

Wonder how Zwartie  is doing ? It's good intel for us, or at least me. I have wondered how fast I could travel under gravity feed at a sustained speed in an emergency. I am glad he put a manual shut off valve in place until he gets it fixed.
George

[Hersey289]

Update:

I spoke to Ben late this afternoon and forwarded your fuel pump options to him. He also spoke to Randy who was also a great help. He's shortened the fuel line, removed the filter and it appears it's feeding the carbs well enough. He's shopping at NAPA for a pump. This is a great forum and thanks to all for helping out my good friend.

Rob

[Zwartie]

Thanks everyone for the great advice and offers for help. This forum is amazing! So yesterday morning I removed the fuel filter and ran the fuel line more directly to the carbs. The bike actually ran really well with just a hint of hesitation when riding at 80mph into a head wind. Picked up a fuel pump yesterday afternoon at a Napa store and installed it this morning. Will post photos of the install and give a report on how it's working. We're in Bozeman, MT this morning and ready to head out on the road en route to Surrey, BC - will get there tomorrow afternoon.

Thanks again!

Zwartie

[movenon]

Thanks everyone for the great advice and offers for help. This forum is amazing! So yesterday morning I removed the fuel filter and ran the fuel line more directly to the carbs. The bike actually ran really well with just a hint of hesitation when riding at 80mph into a head wind. Picked up a fuel pump yesterday afternoon at a Napa store and installed it this morning. Will post photos of the install and give a report on how it's working. We're in Bozeman, MT this morning and ready to head out on the road en route to Surrey, BC - will get there tomorrow afternoon.

Thanks again!

Zwartie

Have a safe trip !  Looking forward to what pump you ended up with and trip report. Watch out on the roads up there. 

George

[Zwartie]

I installed the new fuel pump on Thursday morning in Bozeman, MT

Here's the fuel pump from Napa. It came in a kit with a fuel filter that threads into the inlet side (not shown)


Here's the pump assembly installed and ready for functional testing


And here it is cleaned up and ready to ride


Time to clean up the work area


We rode 915km on Thursday from Bozeman, MT to Ellensburg, WA and then 360 km yesterday to Surrey, BC. The FJ is running great! Thanks everyone who offered help and advice!

Zwartie

[red]

I installed the new fuel pump on Thursday morning in Bozeman, MT
Here's the fuel pump from Napa. It came in a kit with a fuel filter that threads into the inlet side (not shown)
The FJ is running great! Thanks everyone who offered help and advice!
Zwartie

Zwartie,
Hey, no fair!  A search for the "EFT-3" FACET posi-flo electric fuel pump" produces nothing valid.  A search of NAPA gives no results for FACET at all.  NAPA chat techs are equally useless.  What is the FACET Part Number of that gadget, and the NAPA in-house Part Number (they said it would be on the receipt)?  FACET makes a dozen different units.  

My old FJ needs a fuel filter, so it will need a fuel pump.
Nice work, anyway.    

Cheers,
Red

[Flying Scotsman]

If your riding the bike in your avitar it wont have a fuel pump its gravity fed.

[red]

If your riding the bike in your avitar it wont have a fuel pump its gravity fed.

Flying Scotsman,

That is true, the 1985 FJ1100 has no fuel pump, originally.  However, there is not enough "gravity feed" fuel pressure to use a fuel filter, without having a fuel pump.  Since I want to install a fuel filter, I will have to add a fuel pump.  Not a large problem here, but the fuel pump that Zwartie used looks small, and it's capable.

Cheers,
Red