Fuel Pump Issue

Update for the following post http://www.r1-forum.com/forums/showthread.php?s=&threadid=134832&highlight=running+lean Well it’s turns out my fuel pump wasn’t dead just broken. I never bothered to take it apart before because both the Yamaha and Clymer manuals said there was no point, because there are no replaceable parts. Well that may be true but it doesn’t mean there isn’t anything that can come lose and stop the pump from operating properly as I found out. Once I took it apart (sorry no photo’s) a little plastic cap fell out and the o-ring that seals the feed line from the upper and lower portion of the fuel pump house was jammed sideways in the upper casing. With a little work I was able to remove the o-ring from the upper casing without damaging it. On the lower casing there is a recess in the feed line that’s just the prefect size for the o-ring to sit on. Then the plastic cap snaps down on top of the o-ring to keep it in place. Once that was done the upper and lower casing snapped together in a much tighter fit I had to give them a good push to snap together as apposed to them just falling apart when I disassembled it. Once the fuel pump was back in the tank it no longer leaks and the bike fired right up. I can only guess that the impact from the crash caused the cap to loosen and the o-ring slowly worked it’s way up, allowing fuel to drain from the tank and partly blocking the fuel flow not allowing the pump to deliver the proper amount of pressure needed to run the bike. The $882 the local dealer wanted to order a new pump was all the motivation I needed to try and disassemble the pump :scared I hope this post might help anybody else that runs into this strange and very rare problem.

I"m putting this as a sticky,even if its a rare occurence. Thanks for the digging!

good dig man

i picked up an extra fuel pump just in case you gotta love ebay 65 bucks

I may have a similar problem because my fuel pump is leaking also. I ordered a new O-ring for it to try and fix myself but because of multiple switch/sensor malfunctions (bike theft) the bike went to the shop. They said that the fuel pump voltage was out of specification; does anyone know of a way to fix the voltage? I bought the fuel pump from a salvage yard and they are sending me a new fuel pump to replace this one (they don't want the old one back since it's "broke") but I figured if I could fix it I would either have a spare or I could get a few buck for it? Any ideas or suggestions?

The fuel pump doesn’t have a voltage that you can measure. There could be a problem with the voltage it is receiving. But that wouldn't be a problem with the fuel pump. You can measure the resistances for both the fuel level sensor and the fuel pump plug. But it's more or less you have resistance or you don't. aka the pump or sensor is blown. As for the leaking there may be nothing wrong with the o-ring like in my case. It just wasn't being held in place properly because the cap that seats it came lose. Just my 2 cents

i took one apart and can't remember if it has more gaskets than the Oring. any of you know?

The only gaskets I can remember were between the pump and the fuel tank and the o-ring. Now if you take the pump completely apart by removing the pump from the housing there is another gasket that keeps it firmly in place.

deconsly that is what i thought oring + gasket its a good thing this is my spare tank. it can wait thanks

Sorry to pirate the post here gents, but where the hell is the fuel filter on a 04 R1? Nothing in the manual. What gives? It sort of coincides with the fuel pump topic...sort of. Thanks for the useful info. Cdawg

The fuel filter is built into the fuel pump and cannot be replaced only cleaned. You have to remove the fuel pump from the tank and then proceed to separate like 5 snaps then the upper and lower housing should separate. The o-ring that seals the upper and lower housing via the fuel feed line should have it held together fairly well so be careful not to damage anything. You should now be looking at the filter attached to the bottom of the pump itself. It can also be removed with a little care for better cleaning.

Great thanks. There's is nothing in the manual about cleaning, at least that I can find. Any recommendations on cleaning intervals? Thanks for the update..

At the start of every season,along with calipers cleaning,extensive chain care,some bolts torquing,etc.

I've just experienced something similar to this, different symptoms, but same outcome. To clarify - The fuel filter CANNOT be cleaned or replaced!! The above mentioned piece is a screen, not a filter. The filter starts at the top of the pump assembly and runs down the side to where there is a galley at the location of the fuel inlet, right at the screen. Here is a link to my issue: http://www.r1-forum.com/forums/showthread.php?s=&threadid=141900 The lesson is that the o-ring located at the fuel outlet supply line HAS to be inline and seated correctly. This thing is fragile and can distort easily.

I had to replace my fuel pump at 11,000 miles....ran fine till 3 days ago...now its doing the same thing...first one was under warranty.......this one should be too since its a recurring problem with a part already replaced.....i have 21,600 miles on the bike now...... This starting to annoy me.....I would LOVE to find an aftermarket alternative . Maybe i will tear it apart if they dont warranty it straightout.

always keep your tank full, by the looks of your mileage it would seem you commute alot . Perhaps on this commute you should check with the gas stations you're getting your fuel from and see if they even change thier gas pump filters..alot of places ignore this. that filter gets by passed and in goes the crud into youyr tank screwing up your fuel pump...food for thought anyways

Originally posted by laubin always keep your tank full, by the looks of your mileage it would seem you commute alot . Perhaps on this commute you should check with the gas stations you're getting your fuel from and see if they even change thier gas pump filters..alot of places ignore this. that filter gets by passed and in goes the crud into youyr tank screwing up your fuel pump...food for thought anyways Dont really commute alot.....I just ride alot........off Fri,Sat,Sun every week.....Florida weather is good all year round for riding, hence the miles......I understand what ya mean on the fuel stations, I have had bad gas (no pun intended) on several occasions.....think i am gonna tear her down tomorrow morning and see what up with the fuel pump myself....after i call Yamaha and see if they will warranty it. thanks for the info

its not a bad job really... maybe you can find a station who actually adheres to the law...:machinegu

Originally posted by laubin its not a bad job really... maybe you can find a station who actually adheres to the law...:machinegu Man.....I have complained about the gas in this town till i was blue in the face...I am so done with bitch'n I just make sure i ALWAYS have HEET (water remover) in my tail...just in case With Floridas water table being so HIGH and the upkeep of the underground tanks being such a LOW priority...I try not to take chances...I try to stick with newer stations as they may have better tanks....maybe I am just hoping:dunno I wish there was some kind of test available to the consumer so thye could go to AutoZone and buy one for 5 bux...go to the gas station and as they are pumping could dip a test strip in the fuel and tell how much water is in it...or a clarity test for debris....Big Oil would hex that in a jiff though...........maybe thats my in to the Millionaires club......DYI Fuel Test kits.......:dollar :dollar Alright Phookers....don't steal my idea , or i will kill you till you die from it.....:boom

I went for a quick ride last night and everything was fine. i tried to start it this morning and when i turned the key on i noticed the fuel pump didn't prime the cylinders. i try to start it and it just cranks and cranks without starting. i have checked all of the fuses and relays and connections i can without taking the tank off and they all seem fine. i sprayed starter fluid in the intake and it started but then died within a second after. i have a pciii hooked up as well and was put on by the previous owner. i have never had a problem with anything over the past 6k miles and 2 months i have owned it. what is wrong now?

as with anything verify the problem..you've answered alot already- you have spark and air( it ran briefly)..but no fuel... and now the pump has gone out. Fuses are ALL good 'eh? - do you have power to the fuel pump? keep us posted

I"m starting to have problems with mine too...not bad after all that mileage. Symptoms: -Bike stalls past 200F -Bike smells a lot (fuel smell) -Bike works fairly well when temp drops -When that occurs,the spark plugs are light grey (compared to light tan usually) Sounds like vapor lock but in the fuel pump... :crash

when i disconnect to fuel pump and test the wires going to it they are hot and getting the full 12 volts and i have tested the wires in the fuel pump and they are flowing just fine. it's just whenever i connect the fuel pump suddenly i get no power. i think it is a problem with the ground wire so i am curious. can i just run a separate ground wire to the block or somewhere to try to fix it or is the ground wire supposed to go back through some computer or sensor on the bike somewhere? thanks.

Excuse me jumping in here, but I don't think the wire(s) would be getting warm if you had no earth. Sounds like you have an earth but something (duff fuel Pump - stuck ?) is drawing too much power. If you had no earth there would be no complete circuit and no warm wires.

i kinda thought the same thing but was not sure and am running out of ideas so thought it might work. if that is not the case then what is?

I guess the expensive but likely solution is substituting the fuel pump with a new one. Alternatively strip down your fuel pump to find whats "stopping" it. If its a fundamental problem with the windings it will be no better when you reassemble and test. If you find a mechanical problem like a dislodged part which you can relocate, problem probably solved.

i've got the fuel pump apart right now and everything looks good. the mechanics of the fuel pump work fine because when i hooked it up directly to the battery the fuel pump came on and started pumping immediatly. i am in the process of trying to get a hold of a different fuel pump to see if that is the problem somehow.

All I can add is if that it works well when hooked directly to the battery then maybe the problem does lie elsewhere. Lets see how a substitute pump fares!

i had a friend come over with his 02 r1 and we swapped fuel pumps and power commanders to see if either of those were the culprits but that was a negative so as a last hope we swapped relays(the one right next to the ecu) and turns out that was my little devil. lucky for me another friend happen to have one laying around that he didn't need so this whole project didn't cost me anything but time. i thought that might be the problem i just didn't know of a way to check a relay. is there a way to check a relay without just trying a different one that you know works? thanks for the suggestions.

i have an 04 i rebuilt and the fuel pump was messed up from the wreck and i took it out and put it back together and it worked fine for a while till i was riding the other day and i took off from a stop sign and the bike just shut down and would not start the gauges were showing 40 when i would try to start it i was wondering if anyone knew this code i am assumeing it is the fuel pump but anyway it just all the sudden started back up 30 min later but now it sputters sometimes if anyone knows this code let me know otherwise its back into the tank i go.

No code 40 in the service manual...41 is lean sensor cut-off switch.

hey man i laid my bike over and im not getting any gas and will not start. because when i spray sum B-12 in the chambers it will start right up and stay on for a few seconds. so im hoping its the same thing that happened to ur bike. if it is that will solve all my problems. if you have any suggestions just email me or respond to this to help me.

hi can you tell me how much horse power a 03 r1 has ?? and i just got it all running and when i rev it up and let off it pops out the exhaust any ideas why ??

hi i put this 03 r1 in a yamaha banshee and i had to buy a extrenal fuel pump am i gonna be good with that or do i need to regulate it down some ??

THANKS! I had the exact same problem, did every check in the manual, had the correct resistance but couldnt locate the problem. Pulled it apart and thought the O-ring looked strange wedged in up top. I decided to check the threads JUST in case someone else ran into this problem. Fixed--- WORKS LIKE A CHARM. Thanks! Update for the following post http://www.r1-forum.com/forums/showthread.php?s=&threadid=134832&highlight=running+lean Well it’s turns out my fuel pump wasn’t dead just broken. I never bothered to take it apart before because both the Yamaha and Clymer manuals said there was no point, because there are no replaceable parts. Well that may be true but it doesn’t mean there isn’t anything that can come lose and stop the pump from operating properly as I found out. Once I took it apart (sorry no photo’s) a little plastic cap fell out and the o-ring that seals the feed line from the upper and lower portion of the fuel pump house was jammed sideways in the upper casing. With a little work I was able to remove the o-ring from the upper casing without damaging it. On the lower casing there is a recess in the feed line that’s just the prefect size for the o-ring to sit on. Then the plastic cap snaps down on top of the o-ring to keep it in place. Once that was done the upper and lower casing snapped together in a much tighter fit I had to give them a good push to snap together as apposed to them just falling apart when I disassembled it. Once the fuel pump was back in the tank it no longer leaks and the bike fired right up. I can only guess that the impact from the crash caused the cap to loosen and the o-ring slowly worked it’s way up, allowing fuel to drain from the tank and partly blocking the fuel flow not allowing the pump to deliver the proper amount of pressure needed to run the bike. The $882 the local dealer wanted to order a new pump was all the motivation I needed to try and disassemble the pump :scared I hope this post might help anybody else that runs into this strange and very rare problem.