Fuel System Reassembly Problem?

[Mogan]

Chapter 23:

I did all of the above and still no joy.

It was close... it tries to run before dying. If I try to give it gas it immediately dies. Interestingly, when I took the plugs out again to dry them off, #1 & #4 were wet with brown crap. #2 & #3 were dry and clean. It did sort of sound like the bike was trying to run or one or two cylinders before dying--at least after the first/initial run when starting.

Other ideas?

 

[RickL]

How many miles on your bike? Could all the jostling/rearranging have stirred up "sludge" from the bottom of the tank that is now clogging your lines and fouling your plugs?

 

[SkooterG]

Darn, I don't know what to tell you. My fjr displayed the EXACT symptoms yours did. As far as I am concerned, its a fuel starvation issue. Remember, the only thing you did before the problem was mess with the fuel system. So that is where the root cause lies.

Even after my repeated attempts at starting with limited rough idling, I never did check the plugs.

I still think you are NOT getting fuel under correct pressure to the injectors.

Greg

 

[Mogan]

chapter 24:

I checked around all the vacuum lines and sensors dissassembled and reassembled everything. No Joy. BUT, I got an error code this time--16. Either a stuck throttle position sensor or vacuum problem. This is new as it did not light earlier.

I've been playing with this so long I wouldn't see a disconnect wire or kinked hose if I saw one.

A nearby dealer meachanic said he'd come by on Monday if I can't get it going by then.

 

[SkooterG]

Yeah, I got that error code too. Though it was right away when on one of the first attempts to start. That's why I ended up digging out the service manual and entering the diagnostic mode from the display. Still, none of that did anything for me. In diagnostic mode, everything was showing proper values.

Its gotta be the GAS! Somehow, you are not getting proper fuel flow or pressure to the injectors.

Greg

 

[Mogan]

Hail Mary idea-

It's been several chapters since I dissassembled the fuel tank and fuel pump so I am in the middle of that and plan to flush the inside of the tank, toss the gas and refill with fresh petrol.

Another interesting find in the process...

One of the wires on the fuel pump showed visible signs of chafing--undoubtedly from my first attempt at reassembly. I'll repair that. AND, there's a fat o-ring that seals the fuel line flow in the pump and it was not seated flat in the channel.

Wish me luck!!!!!!!!!!!

 

[Mogan]

VROOOOM!

Don't ask me to definitively ID what was wrong. It's wasn't a kinked hose or flooded wet plugs because I played with that numerous times.

But, I taped the chaffed, exposed pump wire and reseated the fuel line o-ring in the fuel pump body and replaced the main fuel pump gasket. I also flushed the tank and dumped the gas, adding 3 gal of fresh gas.

Based on the experience of the last 3 days, I strongly recommend not messing with the fuel pump at all unless the ECU diagnostics indicate a fuel pump fault needing repair. In my case, curiosity is a very nasty *******!

Special thanks to all that pitched in. You guys are the best.

 

[ionbeam]

WELLOHELLO, thanks, whatever. <serious> Glad you got it running!!</serious>

Come meet me at the top of the world

Alan

 

[FJReady]

Well thank goodness you're back to Vrooom, Mogan. It was really beginning to worry me. Like your bike was possessed- any maybe it could happen to any of us.

Criminy. Hope all goes well getting it back together. No more glitches, etc.

Alan, Your photograph looks alot like the top of Mt Washington auto road. Yes? Or Cadillac Mountain?? Great shot. Been up Mt.Wash several times on my Connies. Not of FJR though- probably this fall.

FJReady

 

[RickL]

Hey, great news! Glad you got it working again. Now stop f*ing with it!

 

[Mogan]

Just a few more farkles and I'm done. 90% done with PHIDs. new built-in heatrollers and handgrip heaters with heatrollers. All of the above with awesome switch setup on lower left fairing panel. OOOOOoooo.

Then, Digi gear indicator, speigler brake lines, lower front end to match lowered rear and I'm done. It will be ultra farkled, but hopefully in a tasteful manner.

Final farkle inventory to include:

Lowered Wilbers

Larry's 6 degree risers

Larry's fork brace (if it fits on a lowered front end)

Tanji fuel cell

Dual panel mount heat-trollers

Heat troller for hand grips with dual star heaters and BMW grips

Throttlemeister with custom paint

Escort 8500 radar

Garmin 2610 GPS with touratech mount

AnT rearview camera on tech mount

FZ1 mirrors

bagster tank bra

Autocom pro-7 with Kenwood freetalk/PTT, radar and GPS interface, Creative Micro MP3 and earspeakers

PHIDs with Warchild wiring less current interrupt

Blue Sea 12 circuit bus with relay

Compact nautilus horn

Sargent seat

Cee Bailey screen

unswitched powerlet in right front fairing

Switched dual powerlet in rear

5 function multimeter

Digi gear indicator

Dual hyperlights on license plate

Fenda extender

Radiator screen

Moko sliders

Speigler brake/clutch lines

Galpher rotors

When I get to the finish line, I'll post pics.