Another FJR 1300 2004 Resurrection!! It's been about 5 to 7 years.

[dayven99]

I put plenty of miles on my FJR in ATL before moving here to Vegas and then having my son shortly after moving here. Sadly, all four of my bikes sat while I worked two jobs and took care of my son. I'm finally getting back on the bikes one by one. I read Jammer125 thread and following all the applicable things they are doing. I figured just new battery, new fluids, and tires and it would be ok to get back running. Well new Lithium battery to see it would start but notice I didn't put fuel preservative in only the FJR thinking I would ride again sooner. So, plenty of rust in the tank!! So out with the bad gas and in with baking soda and vinegar (I'm hearing it also breaks up rust). The tank is sitting off the bike with the solution and hopefully I will dump out the rust from the tank tomorrow. I also changed the oil and filter on the FJR. I know final drive and coolant are next on the list once tank and fuel pump are clean. Taking pictures on some of the things I'm doing. Not sure it can fit on the forum.

 

[Pete-o]

That rust in the gas tank is APITA! Good luck.

Pete-o

 

[SkooterG]

Does your fuel pump still work? If so, count yourself lucky. I've dealt with two rusty gas tanks on FJRs in the past few years, an '04 and an '09, and on both the fuel pump was shot also. If your solution doesn't work I highly recommend EvapoRust.

 

[bonami00]

i clean one from a scooter, with vinegar and bicarbonate , after that putted sealer in it
took 3 weeks ( was really bad ) but is now ok

 

[dayven99]

I can't remember what sound the FJR would make to know the fuel pump is working. I thought maybe small blurb in the system. I been away from riding to long.

 

[mcatrophy]

I can't remember what sound the FJR would make to know the fuel pump is working. I thought maybe small blurb in the system. I been away from riding to long.

Perhaps this will jog your memory:

 

[bonami00]

yeah, that is what i am missing, and why my bike is at the dealer ! thank you to let me hear that sound again

 

[dayven99]

Well cleaned up everything but still not hearing "the Fuel pump priming." Need to find a schematic so I can check voltages. Sorry for being quiet lately. Drove Cross country in the slingshot for the 4th to ATL from Vegas followed by a wedding in LA.

 

[dayven99]

Well Been a lot happening but back on the FJR and got a new fuel pump. Took some digging but found an ALMOST exact match. You can see the clean new pump. and the Rusty two pics of the old pump. The new pump has a line missing so I will clean the bottom of the old pump and test it out. Working on a good method to remove more rust.

 

[SkooterG]

Isn't that new clean fuel pump bottom a Gen 2 with no opening for the return line as in your old one at 11 o-clock position? I don't think you can get that one to work?

 

[RossKean]

Isn't that new clean fuel pump bottom a Gen 2 with no opening for the return line as in your old one at 11 o-clock position? I don't think you can get that one to work?

Is it not possible to replace just the electric motor/pump assembly contained within the plastic pump housing? I see lots for sale on eBay but don't recall if anyone has tried this. The usual mode of failure on FJRs seems to be people breaking off one of the fittings on the base...

eBay fuel Pump...

There are also a bunch of Chinese complete units available, but no idea whether they are Gen I Compatible or not.

 

[SkooterG]

Is it not possible to replace just the electric motor/pump assembly contained within the plastic pump housing? I see lots for sale on eBay but don't recall if anyone has tried this. The usual mode of failure on FJRs seems to be people breaking off one of the fittings on the base...

eBay fuel Pump...

There are also a bunch of Chinese complete units available, but no idea whether they are Gen I Compatible or not.

Sure it is possible if the rest of the two-piece housing is serviceable. Both rusted tanks I've dealt with those pieces were NOT serviceable. Primarily the fuel level float and associated wiring/electronics.

 

[Dan Cooper]

Well Been a lot happening but back on the FJR and got a new fuel pump. Took some digging but found an ALMOST exact match. You can see the clean new pump. and the Rusty two pics of the old pump. The new pump has a line missing so I will clean the bottom of the old pump and test it out. Working on a good method to remove more rust.

Is that new pump a Yamaha OEM pump or is it an aftermarket pump? Does it have a built in Fuel Pressure Regulator? Did it come complete with a Fuel Level sending unit float arm assembly?

There are fundamental differences in the Gen 1 fuel system and Gen 2/3/4 fuel systems.
The Gen 1 fuel system has the Fuel Pressure Regulator on the right end of the fuel rail with a fuel return line back to the fuel pump second fitting.
On the fuel pump there is a pressure side fitting to the fuel rail and a return side fitting from the fuel pressure regulator to the pump.

On the Gen 2/3/4 fuel system the Fuel Pressure Regulator is located on the fuel pump housing inside the fuel tank. There is only one pressure side fitting to the fuel rail.

In theory, a Gen 2/3/4 fuel pump assembly might be used on a Gen 1 scooter by blocking off the fuel pressure regulator on the fuel rail and dispensing with the return fuel line. Haven't tried this myself and don't know of anyone who has.
In theory you might be able to swap the bottom cap from the old pump onto the new pump, but then there would be 2 fuel pressure regulators in the system and not sure how well that would work.
In theory there is no difference between theory and practice, but in practice there is. --Albert Einstein

This chinese aftermarket fuel pump assembly does not have the fuel level float arm assembly. The fuel pressure regulator is at the lower left of the assembly.
https://www.ebay.com/itm/1867149318...F7b935+f6WdqZot0I0vzueSn0n6y|tkp:BFBM_P3FiYxl

This pump would fit Gen 2/3/4 FJRs.
.


This one comes complete with the fuel level float arm sending unit.
https://www.ebay.com/itm/1462226570...N279s0nrbaEO9jHVK07NJCZ8lP|tkp:Bk9SR9DJ84mMZQ




Have also come across this fuel level sending unit.
https://www.ebay.com/itm/315266010978



I don't have any first hand knowledge how well any of the chinese aftermarket fuel pump assemblies actually work.

Good Luck,
dan