Fuel pump relay issue

[Neophyte]

I need some advice please. Since yesterday the fuel pump on my 2006 Gen1 is not running and not priming at all. Fuel pump runs when applying power directly to it. It seems the fuel pump relay is not being triggered.

After checking the wiring diagrams and from what I get from testing I suspect it to be the side-stand switch or maybe even the side stand relay.

The side-stand switch has a diode according to the diagram, confirming why I could check continuity only in one way. The "right" way gives me fairly high resistance when I check for continuity. Is that right?

And how do I test the side-stand relay?

I also don't get a C41 error code in case you are wondering.

 

[sixpack577]

You can loop/connect the side stand wires at the plug at the stand, all the side stand switch does is break the circuit.

 

[Neophyte]

I need some advice please. Since yesterday the fuel pump on my 2006 Gen1 is not running and not priming at all. Fuel pump runs when applying power directly to it. It seems the fuel pump relay is not being triggered.

After checking the wiring diagrams and from what I get from testing I suspect it to be the side-stand switch or maybe even the side stand relay.

The side-stand switch has a diode according to the diagram, confirming why I could check continuity only in one way. The "right" way gives me fairly high resistance when I check for continuity. Is that right?

And how do I test the side-stand relay?

I also don't get a C41 error code in case you are wondering.

I got it sorted. It did turn out to be the side-stand switch.

 

[Neophyte]

You can loop/connect the side stand wires at the plug at the stand, all the side stand switch does is break the circuit.

I thought it was the side-stand switch because when I actually tried starting the bike it again didn't start and from there the pump doesn't prime again WITH the side-stand switched by-passed. I removed both the fuel pump relay and the side-stand relay and they both work when 12 is applied. I am really hoping that it is not due to something wrong with the ECU. I will do 1 or 2 further tests just now to try and give more info

 

[sixpack577]

I thought it was the side-stand switch because when I actually tried starting the bike it again didn't start and from there the pump doesn't prime again WITH the side-stand switched by-passed. I removed both the fuel pump relay and the side-stand relay and they both work when 12 is applied. I am really hoping that it is not due to something wrong with the ECU. I will do 1 or 2 further tests just now to try and give more info

Relays can bench test ok, but fail under load, so I would swap or replace the relays before I got another ecu.

 

[Neophyte]

I'll do that first then and report back

 

[Neophyte]

After doing some more testing I found that yes, the orange/white at the fuel relay does get +12v when the ignition is on with the start/stop switch on. I do however get about +10v for the yellow/black too, which is the other side of the coil. When I switch off, both give me -12v.

Is that correct?

If I jump the yellow/black to earth then the relay energizes and the pump runs but still won't start as the injectors are probably not being fired.

 

[mabupa]

After doing some more testing I found that yes, the orange/white at the fuel relay does get +12v when the ignition is on with the start/stop switch on. I do however get about +10v for the yellow/black too, which is the other side of the coil. When I switch off, both give me -12v.

Is that correct?

If I jump the yellow/black to earth then the relay energizes and the pump runs but still won't start as the injectors are probably not being fired.

My gen2 left me stranded one day and I had to hot wire the pump to get home. Relay tested ok on the bench but, I later found that it would fail under load. I ended up ordering 2 relays so I could carry a spare with me.

 

[Neophyte]

My gen2 left me stranded one day and I had to hot wire the pump to get home. Relay tested ok on the bench but, I later found that it would fail under load. I ended up ordering 2 relays so I could carry a spare with me.

What I also found is that I have no spark either. I don't even get the FI light to come on (which does work btw). I unplugged all sensors to "force" the light to come on, giving for just a few seconds C13 and C14, still no light and now nothing at all even after I disconnect and reconnect the battery.

 

[Neophyte]

Okay, so today I was going to take the bike in to JR Racing here in Pretoria to have a look for me as they need to tune it on the dyno in any case. After plugging everything back in properly before taking it, I decided to check one last time, and she actually did fire up after some struggle, as the pump was running again etc. She didn't sound happy though like missing badly but somehow not being very rough. Eventually, I found it wasn't getting any spark on both #1 and #4. The same coil and sparkplug then worked on #2 and #3. I checked the wiring for continuity with no problems at all, and even an LED with 1k resistor would light up on #2 and #3, like the spark plug would fire, but being dead on #1 and #4.