Gen I won't start after tank removal

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MntnBoy

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Oct 13, 2008
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Location
Morristown, TN
I bought my 05 last fall and have been enjoying it ever since. As I live in the south, I ride on a regular basis all year long and have had the bike started and running up to a couple of weeks ago. I've never had any problems starting the bike. This weekend I removed the lower side fairings, tank, and seats to do a little farkling and to service the bike with new plugs, oil, and air filter. After adding a fuse block up front (connected to a 30 amp relay), I did a bit of insulating under the tank. I applied 1/2" of ceramic wool covered by a cut piece of space blanket, attached using metal duct tape. I cut out for all the hose and electrical connectors.

A 6" LED light bar with brake light flasher modulator (Back Off) was also added to the rear license plate holder. All wires and connectors were crimped and soldered where possible, shrink wrap taped, and neatly installed.

After I get all my mods done, I put the bike back together and it won't start. Doesn't hit a lick. I read the forum posts on holding the throttle in the WOT position and cranking it for 10 to 15 seconds. Still nothing. Charged the battery thoroughly after I heard it start to sound a bit slower (before it got too run down). After an hour, try it again and this time it hits once (poomph), then nothing. I don't smell any gas, so I tilt the tank back up and double check the connectors. Everything looks good. I reseat the fuel hose and electrical connectors again. I hear the fuel pump engage when I switch on the system, but I never smell any gas. Put fresh gas in the tank, and yes, the kill switch is in the run position with the kickstand up (bike is on the centerstand). I hold in the clutch (in neutral) as I press the starter button.

I generally don't press the starter switch for more than 6 seconds at a time. After several attempts, I let it rest for 30 minutes or so and tried it again. The flashers activated this time but the display did not return any kind of code. I read on one of the posts where the mode may be incorrect and needs to be "reset". I've been servicing my bikes for decades and have torn down and reassembled many a carb system, but have never fooled with electronic fuel injection. Guys, I need your help in figuring this problem out. Any suggestions?

 
Disconnect fuel line where it attaches to fuel rail, cycle igntion on and make sure fuel pump is pumping gas. Have a cup available to collect the fuel. Then reconnect and try again.

One time I had my tank off like yours it woudn't start. The above trick worked for me. I figure either I had air in the line or pump, or it finally just decided to start after hours of attempts.

 
I'd cycle the ignition on and off a few times and try it again.

Sometimes the ignition switch contacts get intermittent and it'll happily crank away, but won't start.

My 05 will throw a code 19 if I crank it long enough in that condition.

 
Disconnect fuel line where it attaches to fuel rail, cycle igntion on and make sure fuel pump is pumping gas. Have a cup available to collect the fuel. Then reconnect and try again.
One time I had my tank off like yours it woudn't start. The above trick worked for me. I figure either I had air in the line or pump, or it finally just decided to start after hours of attempts.

I thought I would try that during lunch today to see if I'm getting any gas. She just may be cantankerous now that I've exposed her underside...

Thanks guys,

~D

 
Make sure you didn't hook the fuel lines in reverse. Had the same problem during my "rebuild" and I had them connected backwards. Once I fingered it out she started right off the bat. I'm an idiot.

 
Make sure you didn't hook the fuel lines in reverse. Had the same problem during my "rebuild" and I had them connected backwards. Once I fingered it out she started right off the bat. I'm an idiot.
I'm callin' BS on this.....the fuel feed uses a clip-on connectors at the fuel rail and tank. The fuel return uses slide/clamp-on connectors at fuel rail and tank.

Oh, I'm not arguin' the "idiot" part, though. :****:

 
Make sure you didn't hook the fuel lines in reverse. Had the same problem during my "rebuild" and I had them connected backwards. Once I fingered it out she started right off the bat. I'm an idiot.
I'm callin' BS on this.....the fuel feed uses a clip-on connectors at the fuel rail and tank. The fuel return uses slide/clamp-on connectors at fuel rail and tank.

Oh, I'm not arguin' the "idiot" part, though. :****:
Would be tough, but if anyone could do it, he's the man. B)

 
Unhooked the fuel line at the rail and cycled on the power -- no fuel coming out...
[SIZE=14pt]Ruh-Roh![/SIZE]

Do you know how to get in to the "DIAG" mode?

Turn key off. Hold down both buttons on LCD display. Turn key back on. Continue holding both buttons until display changes to "DIAG" (9-10 seconds). Release buttons. Then press both buttons together AGAIN until display changes to :01.

You are now in the "DIAG" mode.

Now, turn your killswitch to OFF...and press the right button on the LCD display to cycle to DIAG mode #09...that's the "Voltage Check" mode.

Now, with your fuel line disconnected from the fuel rail and the end of the line placed in a suitable container, turn your killswitch ON. This will turn your fuel pump on. You should hear it running. And if it IS running, it should be spewing fuel into your container at a prodigious rate.

If it doesn't run, check the electrical connector going to the pump. It's the connector closest to the right side of the bike. On my Gen I, it's the black connector. The other, white connector is the fuel gauge connector, closest to the left side of the bike.

Raising the tank CAN stretch the hell out of the wire bundle running to the tank, and if you lift the tank too far you conceivably unplugged the fuel pump connector, OR yanked wires out of the back of the connector.

If the pump IS running, but not spewing fuel like a Danny Thomas spit-take, get back and report.

 
Make sure you didn't hook the fuel lines in reverse. Had the same problem during my "rebuild" and I had them connected backwards. Once I fingered it out she started right off the bat. I'm an idiot.
I'm callin' BS on this.....the fuel feed uses a clip-on connectors at the fuel rail and tank. The fuel return uses slide/clamp-on connectors at fuel rail and tank.

Oh, I'm not arguin' the "idiot" part, though. :****:
Would be tough, but if anyone could do it, he's the man. B)
FUZZY BALLS!! I couldn't agree more Rad... That guy can do anything!

:jester:

 
In the immortal words of Forrest Gump, "Stupid is as Stupid does..."

It was a long weekend working up close and personal on the old gal...I believe the old eye sight was starting to get a bit blurred towards the end of Sunday (farkin bi-focals).

I indeed had the two fuel line connectors ass backwards. And yes, when I removed them both I could plainly see the barb for the quick disconnect line and the hose barb for the slip on line.

I too am an idiot. She fired right up when I had the hoses connected properly. Thanks guys for all the help and info...this site is a great asset to guys who like to work on their own machines but sometimes get things wrong.

At least all my electrical mods worked flawless (with the help of several postings from those who have came before me.)

A great big THANK YOU for all the information and help this forum has to offer. I'm a long time rider (over 30 years) but new to the FJR. I absolutely love it and have a short trip (2000 miles) planned in May to Texas and back. Can't wait to get in the saddle for two weeks!!

~Don

 
In the immortal words of Forrest Gump, "Stupid is as Stupid does..."
It was a long weekend working up close and personal on the old gal...I believe the old eye sight was starting to get a bit blurred towards the end of Sunday (farkin bi-focals).

I indeed had the two fuel line connectors ass backwards. And yes, when I removed them both I could plainly see the barb for the quick disconnect line and the hose barb for the slip on line.

I too am an idiot. She fired right up when I had the hoses connected properly. Thanks guys for all the help and info...this site is a great asset to guys who like to work on their own machines but sometimes get things wrong.

At least all my electrical mods worked flawless (with the help of several postings from those who have came before me.)

A great big THANK YOU for all the information and help this forum has to offer. I'm a long time rider (over 30 years) but new to the FJR. I absolutely love it and have a short trip (2000 miles) planned in May to Texas and back. Can't wait to get in the saddle for two weeks!!

~Don
[SIZE=8pt](**** it hurts to do this.....)[/SIZE]

Apologies to odot.

 
Last edited by a moderator:
In the immortal words of Forrest Gump, "Stupid is as Stupid does..."
It was a long weekend working up close and personal on the old gal...I believe the old eye sight was starting to get a bit blurred towards the end of Sunday (farkin bi-focals).

I indeed had the two fuel line connectors ass backwards. And yes, when I removed them both I could plainly see the barb for the quick disconnect line and the hose barb for the slip on line.

I too am an idiot. She fired right up when I had the hoses connected properly. Thanks guys for all the help and info...this site is a great asset to guys who like to work on their own machines but sometimes get things wrong.

At least all my electrical mods worked flawless (with the help of several postings from those who have came before me.)

A great big THANK YOU for all the information and help this forum has to offer. I'm a long time rider (over 30 years) but new to the FJR. I absolutely love it and have a short trip (2000 miles) planned in May to Texas and back. Can't wait to get in the saddle for two weeks!!

~Don
[SIZE=8pt](**** it hurts to do this.....)[/SIZE]

Apologies to odot.
Oh Gawd, I haven't laughed this hard in a decade! ODOT to the RESCUE! Whodathunkit, huh? Pretty impressive, Mr. Odot, now, can you make my 79 kz1300 quit burning oil at a prestigious rate?

Back to topic, I'm very glad you got her running again - what a pleasant surprise - an easy fix... after a long weekend - and now all is good. Changes the whole mental 'tude, huh? :clapping:

 
When you get down to texas in may you can buy me a case of col' beer. I prefer keystone light....it's cheap.

 
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