Need help

[Pipefighter248]

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Did you replace the fuel filter tower? The big black thing that the pump, regulator, fit into? I had the same problem and replaced the fuel pump (little round motor) (fuel pressure regulator) Small metal L shaped thing, all for nothing. Then I found out the fuel filter is the large black thing that all that stuff plugs into. Replaced that and click....click.....boom ! she was back to haulin azz! I don't know if this will help..So I'll also chuck in a free

Good luck brother!

Looking at the microfiche it says the fuel filter is the part that I thought was the regulator.
Are you sure it is in the tower?
#2 on the drawing; fuel filter assy.

Yup! I did everything your going through as well, it sucks I know,! but this is what I had to do to fix my problem. Here is a a better diagram. After finally fixing my problem with a new filter, I decided to cut open the big black tower and found inside a cheep cardboard or paper folded filter that was plugged up with gunk! I wish I took photos of it that way I could show ya but I did not.

Sounds good.
I changed it out last night anyways, but can't get a break in the rain.

 

[DJ_JONES]

Mine has an external fuel pump (Turbo) but I guess you are saying that the strianer could still be clogged?

 

[turbojonn]

When you installed or took out the turbo did you shut off the gas? I know it's simple, but who knows? Mine will still run with the gas shut off, it just won't rev very high. Did you install any turbo spec vacuum restrictors or check valves? Check to make sure the vacuum line to the map sensor isn't getting kinked when you shut the tank. Sometimes those lines will kink at the very last degree of thank closure. I know you've checked it already, but it's worth a look, at least the map sensor line. Good luck with weather and the fix. How's your charging system and battery voltage? If you run out of spark you'll loose top end. Get a voltmeter and check your battery when revving, and your stator output. Somebody once had an issue with a rev limiter getting weird. I know they kick in WAY higher in rpm, but maybe somebody knows how to check that circuit.

 

[heavyjeffd]

Not that my suggestion will be much help, but is there a strong smell of gas after you ride it?

I've seen bikes do exactly what you are explaining that are just running REALLY rich. Possibly larger injectors with the turbo?

Just a thought.

 

[turbojonn]

Yeah, that's a good idea. Maybe something along the same lines too: a stuck injector? If just one was stuck you could tell by pulling the plugs and checking for a sout coverded tip. Good luck.

 

[Sloto200]

another shot in the dark here... what if one of your coils is going out... it could be heating up and and building up resistance and causing you to go down a cylinder...

 

[Pipefighter248]

Don't really know.
Can't try my last change due to rain.
But I am fairly confident that changing the fuel pump hosing with my orig. will work out.
It is the last thing that was different or changed on the bike.
I'll update the post once I get to try it out.

 

[DJ_JONES]

Pipe do you have a after market kill teather on the bike?
This was posted to me on antoher board....(worth a shot)

"if u got a after market kill take it off and wire stock and try it..this was a problem for me...felt like bike fell on its face but didnt really show signs of breakin up..i think it lost voltage in teather"

and

" Good one greg, that happen to me.
Connections to back of vortex kill was bad and under a lot of rpm it was vibrating and killing the motor just enough to be a pita. "

 

[Pipefighter248]

Pipe do you have a after market kill teather on the bike?
This was posted to me on antoher board....(worth a shot)

"if u got a after market kill take it off and wire stock and try it..this was a problem for me...felt like bike fell on its face but didnt really show signs of breakin up..i think it lost voltage in teather"

and

" Good one greg, that happen to me.
Connections to back of vortex kill was bad and under a lot of rpm it was vibrating and killing the motor just enough to be a pita. "

No sir I don't.

 

[DJ_JONES]

OK.

I bought new fuel line and new fuel pump is on the way.
All electronics that are not needed are coming off to start from bare minimium.
I will let you know what we find.

 

[Pipefighter248]

Good luck DJ.
Hope you find your problem.

 

[Pipefighter248]

Did you replace the fuel filter tower? The big black thing that the pump, regulator, fit into? I had the same problem and replaced the fuel pump (little round motor) (fuel pressure regulator) Small metal L shaped thing, all for nothing. Then I found out the fuel filter is the large black thing that all that stuff plugs into. Replaced that and click....click.....boom ! she was back to haulin azz! I don't know if this will help..So I'll also chuck in a free

Good luck brother!

Ding; Ding; Ding!

We have a winner!!!!

Finally got to take the bike out again tonight even though the roads were still damp and she's back.
Swapped the replacement fuel pump housing with my original that I had modified for the turbo and it worked.
Glad she's back on the road with full power again.
I would like to thank all those that helped and suggested possibilities.
I appreciate it.

 

[Pipefighter248]

Now let's try to help out DJ who is having the same problem.
I know how frustrating that it is. Good luck DJ.

 

[Pipefighter248]

OK.

I bought new fuel line and new fuel pump is on the way.
All electronics that are not needed are coming off to start from bare minimium.
I will let you know what we find.

Def. check for a problem in the fuel system.
If you are using an internal pump housing, you may want to check it out also.

 

[johnstein]

did you change out the fuel filter ? i had a similar problem but when the rpms capped the fi light would flash  till i turned the key off then on again turned out being the filter , other than that i dont know it definatly sounds like a fuel problem , any chance when you pulled the plugs you did a compresion test ?

sorry pipe , been following your thread , guess i should ve described it a little better

 

[Pipefighter248]

did you change out the fuel filter ? i had a similar problem but when the rpms capped the fi light would flash till i turned the key off then on again turned out being the filter , other than that i dont know it definatly sounds like a fuel problem , any chance when you pulled the plugs you did a compresion test ?

sorry pipe , been following your thread , guess i should ve described it a little better

No problem John.
I thought you were talking about the strainer; and to be completely honest, I never knew that the fuel pump housing(black part) was a filter also.
Just glad it's taken care of and done.

 

[johnstein]

drove me nutz for about three weeks , daniel posted up to call him , i did he got my address and overnited one to me , problem solved , alleast i can now change out a pump in 15 minutes ! blind folded !

 

[DJ_JONES]

I looked over my gutted fuel pump housing and it loked ok with no restrictions.
I had purchased a RPM Interneal Fuel Pump cover ( http://www.rpmcycleperformance.com/products_suzuki.htm )
so I went ahead and removed the stock housing completely and installed the RPM unit.

A ssoon as my new WALBRO 255LPH External Inline Fuel Pump GSL-392 gets here I will start putting it back together. I have removed all the "extra" electronics that I have puyt on the bike so that now only the Power Commander will be the only thing on the bike. We shall see.

 

[Rhythm]

Good to hear Nathan. Is the internal fuel filter part of the pump or two separate pieces you can buy individually?

 

[Pipefighter248]

Good to hear Nathan. Is the internal fuel filter part of the pump or two separate pieces you can buy individually?

I don't think you can buy the black housing piece seperate.
Would have to look though.