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Old 09-30-2012, 11:37 PM   #1 (permalink)
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Default 03' 636 Fuel Pump Circuit Trouble

03 636 Fuel Pump won't turn on.


To make a long story short I cannot figure out why my Fuel pump relay circuit will not work. I have replaced the main harness (needed it, due to mice) and installed a new fuel pump. I checked the relay switches for the ECU and Fuel pump using the batt to activate the electro mag and a multi meter to check the switch and they operate correctly. I have no FI codes. The kick-stand switch, the engine kill switch were tested and working. I also replaced the tip sensor !

I then started to check the voltage potential for the relay parts. (see img)
The ECU relay flicks on (I can feel it trigger) and has almost total voltage drop across the BR &BK/Y.
The Fuel Pump relay does not activate, but has 11.85v on either side of terminal R & BR/Y.
The BR/Y go directly to ECU, is my ECU toast? I have searched everywhere I could and I am out of ideas, someone help please!




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Old 10-19-2012, 11:14 AM   #2 (permalink)
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Hey man if you need a fuel pump for the beast I have a additional one..Ill let it go for 60.00

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Old 12-06-2012, 03:18 PM   #3 (permalink)
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Default New Fuel pump

I bought a brand new fuel pump, and a new/used ecu on ebay, changed out and still having same issue. So Iíve basically replaced every part in the fuel system and still no dice. Anyone have any suggestions as to what may cause the Fuel pump circuit not to work?


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Old 12-07-2012, 04:00 PM   #4 (permalink)
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Give me till sunday and I'll think about it and post up some ideas/theories. I've got 2 finals tomorrow and can't put much time into it till then. Quick question, are you getting spark?

And I'd start checking the resistance everywhere as well, if you haven't already

Also, where are you located?
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Old 12-07-2012, 04:18 PM   #5 (permalink)
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When you installed the new tip over switch did you make sure the arrow was pointing up?
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Old 12-07-2012, 08:56 PM   #6 (permalink)
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I will double check, but I don't think it will screw in if it is upside down. Thanks for response, any suggestions are much appreciated!


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Old 12-07-2012, 08:59 PM   #7 (permalink)
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Quote:
Originally Posted by Steel View Post
Give me till sunday and I'll think about it and post up some ideas/theories. I've got 2 finals tomorrow and can't put much time into it till then. Quick question, are you getting spark?

And I'd start checking the resistance everywhere as well, if you haven't already

Also, where are you located?
I will have time to check these Sat night or Sunday morning. I will post pics and results by sunday night.


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Old 12-07-2012, 09:31 PM   #8 (permalink)
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Bike is located in central mass



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Old 12-10-2012, 01:11 AM   #9 (permalink)
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Yes, I just tested everything again. I was a bit off on the diagram I provided (corrections below). I have 4 of the same to swap out with, one for ECU relay and one for the Fuel Pump relay from the old wire harness and two others from the new/used harness I just put in. All of the relays seem to work fine on ECU circuit but not on Fuel pump. Jumping the relay causes the fuel pump to kick on, but just run and run and run (normally it runs for a few seconds and then stops.

I tested each relay and they all seem to test fine. They were tested by providing power and ground from the ECU circuit. Each side was tested for voltage and resistance. On the switch side of the relay I had an average resistance of 100 ohms. Testing for voltage with (lead on ground) I had approx 11.52-11.6V on power and 0.16v on ground side. On the load side of relay resistance with power off was OL and 0.1 ohms with key on. All but one of these relays were very close to each other.

I went back and tested for power a fuel pump See picture below. Upon key turn I got: on red/blk wire 10.75V. On the yellow/red wire I got 0v. ground tested 0.001 ohm resistance(or checking for cont, it beeped). Someone correct me if Iím wrong but the red/blck is power suppy (which it has), black/white is ground and yellow/red is signal?




On the connector red/black connects to black/teal, yellow/red connects to red/white (and has good con straight to fuel pump relay, 0.1 ohms resistance), Black/white is connected to black/yellow (tested good to ground). There is also a 4th wire on the wire harness side brown/black and is connected to what looks like a terminator/blank cap. Both new and old fuel pumps are the same.












I checked the tip sensor and is installed correctly with arrow pointed up.







Tested for spark and ****No spark**** this thing keeps getting worse.
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Old 12-10-2012, 02:15 AM   #10 (permalink)
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You do have an ignition and a key right? I ask because there is a resistor in the stock ignition switch that lets the ecu know the bike is being started with a key and not being hot wired.
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