ZRXDean
Needs a job
Posts: 2225
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posted May 06, 2009 07:12 PM
Help...fuel pump issue.
I have a strange problem with my 2006 ZX10R. Turning ignition on cycles the fuel pump, and it shuts off after a few seconds, as expected. However, when the starter is turned the pump does not cycle back on. If the starter is turned immediately after the ignition is on the bike starts, then dies when the fuel pump cuts out in a couple seconds. So far I've checked;
Swapped fuel pump relay.
Swapped fuel pump.
Swapped ECU.
Battery is 12.5V, all fuses intact.
If I turn the ignition on, wait for the pump to cycle off, then turn the key on and off again, the pump will cycle for a shorter duration the second time, but not at all on the third try. I have to wait 30-45 seconds until it the ignition will activate the pump again.
It ran fine 4 weeks ago. All I have changed is the installation of a Zukinut boost controller, which I unplugged with no effect. I did have to root around the cramped tailsection to get it situated, but I can't see any obvious problems. I had hoped to go to MPS this Friday to tune, and race next weekend at Maxton, so if possible I'd like to figure this out ASAP. Any ideas are appreciated.
Dean
  
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whitehendrix
Zone Head
fails!
Posts: 757
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posted May 06, 2009 09:41 PM
thats very odd.. any codes showing up?
did you swpa the parts one-at-a-time or all at once?
if you swapped em ALL out and it's still doin it, it's probably a wiring probmel i'd say.. now, doubt it onyour bike, but i'll say it anyway..lol
on bikes like mine (cough*dinosaur*cough), the pump is fed temporarily from the starter button until the motor starts.. then, the pulse from the #1/#4 coil signal feeds the fuel pump relay (FPR), and the fpr translates that pulse into a "bump" signal (i call it) to the pump so it pulses instead of flows constantly. i would assume tho your bike has a dedicated fpr channel right fro mthe ECU thats not dictated by ignition, as mine is, but i'm wondering if theres not some sort of tie between the starter button and the fpr..
if this computer wasn't a silly bitch, i'd look at the manual for your bike and trace out the circuits. i know tho as soon as i pop in the CD, the damn thing will shut off completely and send me into a fit of rage. 
just something to consider tho.. probably not a help at all, but maybe it'll help someone else with vintage machinery..lol
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
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entropy
Moderator
Posts: 8671
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posted May 07, 2009 02:04 AM
Dean,
a bell is ringing in my head, i had the same/similar issue several years ago, but my giant ss shows nothing, and i can't remember the specifics.
Something about another relay, not the fuel pump relay, maybe in the junction box???...
It's hell getting old = CRS!
sorry
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This moderator uses moderation in moderation
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ZRXDean
Needs a job
Posts: 2225
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posted May 07, 2009 05:04 AM
Thanks folks, these are good leads, and I've gotten some others as well, along with a night's sleep. I'll report back.
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ZRXDean
Needs a job
Posts: 2225
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posted May 07, 2009 05:27 AM
Woo-hoo, tips from you brilliant forumites helped me find a corroded tip-over switch. Thanks :cheers:
Always humbling to prostrate yourself in front of the machine, pleading for insight. A sign, anything!
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WRECKSHOP
Expert Class
Posts: 359
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posted May 07, 2009 06:33 AM
Where is the tip-over switch located on the 06-07 model ZX-10's ??
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osti33
Needs a job
Posts: 2973
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posted May 07, 2009 06:36 AM
I'm too late but I had the same problem Dean. I cleaned up the corrosion. It came back. I replaced the tip over switch. It went south again. I finally just took the damn thing off and wired in a resistor that was the proper ohms. No more problems with that tip over switch.
Only issue I see with doing it my way is that if the bike tips over it won't shut off but since we have to have teathers anyway I don't think it's a big deal.
Glad you got it sorted. Give em hell at Maxton. 
Ryan
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ZRXDean
Needs a job
Posts: 2225
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posted May 07, 2009 07:00 AM
Thanks Ryan, I cleaned the leads on the harness side, and will bring a spare switch. The resistor idea is a good one.
WS the switch is in the tail, next to the exhaust valve servomotor. It's rubber mounted, and the connector points straight up.
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whitehendrix
Zone Head
fails!
Posts: 757
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posted May 07, 2009 09:01 PM
Osti, did ya use dieelectric grease on it? thats a livesaver there.
good deal on the fix!! i wouldn't have thought that cuz i'm so used to old skool stuff like mine without all that fancy shit to go bad.
carbs, cdi, coils.. pretty much the basics..lol
guess you don't NEED the tip-over switch so long as ya don't fall down! 
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
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