Fuel pump replaced, but now won't run

[coxy]

Hi Guys, I recently replaced the fuel pump on 2004 1200GS. I can hear it prime itself when I turn on the ignition, however the bike won't start at all now, I just end up draining the battery turning it over.
Is there something I need to do to allow the new pump to be recognized by the computer, or do I need to do something to 'calibrate it' in any way?
many thanks

 

[Fifth Horseman]

It should be plug and play.
You've replaced the pump but have you checked that it is actually providing fuel to the injectors? The fact you can hear the pump at ignition-on suggests either the new pump is faulty (motor runs but doesn't pump fuel) or you have made a plumbing error.

 

[DrFarkoff]

Check fuel connections!
Check Throttle cables ALL seated in their holders
and the Main throttle pull cable too

AS above Plug and play No coding

Why did you replace the old one ??? Was it broken ??

If not? Refit it and check if it runs then? if so refit the new one and if it still does not run it must be faulty

You don't need to remove the tank to change the pump relay on an 04 Just the front left side cover

 

[Steptoe]

Remove injector from throttle body, held in place with two small bolts. Keep fuel line attached.
Place/point end of injector into an aerosol spray lid (or similar).
Hit starter button and see if fuel is being sprayed out of injector .
Let us know the result and we’ll take it from there, one step at a time.

 

[Pukmeister]

I had this, turned out the pump internal discharge hose popped off the housing inside the tank after being replaced so was just recirculating fuel within the tank. Sorted with a tiny jubilee clip.


Sent from my iPhone using Tapatalk

 

[coxy]

Thanks for the replies lads.
I took a long trip on it last September and could smell fuel for quite a bit of the trip but couldn't see anything leaking. Then a day or two after I got home the bike would turn over but wouldn't start. I thought there might be fumes leaking out around the ring where the fuel controller/fuel pump are housed hence the smell, so I took that off to replace the seal. I thought while I was there I might as well change the pump and filter attached to it, as a preventive measure more than because I thought there was anything wrong with the pump. But the bike wont fire at all now. I'm at a loss as to what it might be but am wondering now about the initial smell of fuel and am wondering if there is a crack in a fuel line (or somewhere else) that is allowing air in but not much fuel leaking out, maybe just vapor.

 

[squibb34]

The smell of raw fuel vapour is usually the quick release connector, which leaves witness under the tank even if the fuel itself evaporates away.

Your issue needs a back to basics approach, without making any assumptions along the way. We usually start with checking for sparks & fuel delivery direct from the injectors & work from there.

 

[Steptoe]

The smell of raw fuel vapour is usually the quick release connector, which leaves witness under the tank even if the fuel itself evaporates away.

Your issue needs a back to basics approach, without making any assumptions along the way. We usually start with checking for sparks & fuel delivery direct from the injectors & work from there.

Post 4 …. Until that simple thing is done it’s pointless.

 

[MotoRevive]

Remove injector from throttle body, held in place with two small bolts. Keep fuel line attached.
Place/point end of injector into an aerosol spray lid (or similar).
Hit starter button and see if fuel is being sprayed out of injector .
Let us know the result and we’ll take it from there, one step at a time.

This is a good method. And I use it myself.

But MY GOD !! twenty year old injectors go brittle. And the O-rings perish. I've seen decent techs break these off. Lots of brake cleaner or penetrating fluid required to ease them out gently.

A gentle touch is required.