New Fuel Pump Strange noise and then cutout

[LazySatyr]

SO, I've been stranded here in Santa fe for about 4 days now trying to get this fuel pump sorted.

Today I finished replacing it and shoved the whole assembly back in to the tank; new pump new filter new large o rings some new fuel line. Only things i didn't replace are the regulator and the fuel level sensor.

Fired up the bike and lo, it started right up and idled well. Give it some just and it responded but with a strange chugging at certain rpms. Very odd rapid noise chuggachuggachuga until the revs got above a certain point and then normal sounding. Took the bike for a quick test ride and a few miles later it died (which meant a nice walk back for me, pushing the thing beside the road). After that the bike just wouldn't start, i didn't notice a smell of gas after several attempts though. Could the engine have flooded? My bike was running at high AFV earlier which may have been because of the bad pump, might this have flooded before the ECM had a chance to adjust to the new pump?

Does anyone have any idea what might be causing this? Much appreciated

 

[LazySatyr]

Does anyone know what psi the fuel pressure regulator lets through (is rated at). I think it's 45 PSI but i'm not 100%

also i put this pump in :
http://www.oreillyauto.com/site/c/d...ck=Search_C0401_1134144_-1&pt=C0401&ppt=C0025

which puts out 90 PSIfuel pump

 

[gbalias]

what kind of fuel line did you use?

 

[user_deleted]

the stock pump assembly should have a self contained bleed-off style regulator. my recollection is approx. output of 47-50 psi. i'm no injector pump expert but would think your replacement pump output must be regulated. if you suspect your bike flooded for whatever reason do the easy thing first and merely pull the front spark plug. stock size requires 5/8th box wrench or socket. look at it and see if it's fuel soaked and fouled.

 

[LazySatyr]

Sorry guys i think i misled you. The stock regulator is still in there, my worry is that it is broken and may need to be replaced.

Standard black fuel line hose stuff, kind they sell at autozone etc. same as what was in there

 

[gbalias]

you cant use that regular fuel line and submerge it.


the regulator is separate on teh pump assembly. IIRC ic crosses to a late 90's or early 2000's chrysler minivan

 

[gbalias]

i just went through all of this on my bike. lol

 

[LazySatyr]

gballas what do you use instead?

 

[LazySatyr]

gballas. so you're comment may be saving my buell as i was about to give up, i will reassemble today with the fuel line that came with the pump. I used the autozone stuff to connect the new fuel pump to the FPR which didn't fit the new pumps nipple.

Any chance you can remember that part number for that FPR or where I can find it? I'm searching the parts cross reference thread now.

 

[LazySatyr]

also thank you very much indeed!

 

[gbalias]

dang, i cant remember the number. IIRC the dodge part is a tad higher pressure...but is a direct fit, seals and all.


im willing to bet the bend you made with the hose is starving it of fuel.

if the line that came with the pump isnt corrugated, dont use it. it cannot make the u-turn from the pump outlet to the FPR correctly. i would correct this issue before buying a $80 FPR. if you cant source the corrugated hose, ive got some i can send you.

 

[UMDterp13]

Why not just buy a whole used pump assembly? Is there really that big of a fear someone online is going to sell you a bad part?

I've had several 50k+ bikes & pumps were without issue.

You can get used assemblies for $50-100 from other members or spend $75-250 on new parts and, as discovered, possibly put it back together incorrectly and fix nothing

 

[user_deleted]

Any chance you can remember that part number for that FPR or where I can find it? I'm searching the parts cross reference thread now.

here ya go:

Fuel pressure regulator

I discovered the Dodge caravan FPR cross-over. Search for a FPR from a 1996 DODGE CARAVAN 3.3L V6 OHV.

CHRYSLER CIRRUS (1995 - 2000)
CHRYSLER GRAND VOYAGER 2000
CHRYSLER SEBRING (1996 - 2000)
CHRYSLER TOWN & COUNTRY (1996 - 2000)
CHRYSLER VOYAGER 2000
DODGE CARAVAN (1996 - 2000)
DODGE GRAND CARAVAN (1996 - 2000)
DODGE NEON (1995 - 1996)
DODGE STRATUS (1995 - 2000)

 

[nicholas900]

I replaced my pump with a new assembly because it was loud. The regulator is stamped 338 kpi (converts to 49 psi).

Also worth mentioning not all the pumps have corrugated tubing. Some have rubber fuel line. You can get fuel line in a submersible grade at Napa, or just about anywhere. You do need to be sure it's submersible grade though.

 

[LazySatyr]

So i've got the thing fixed, the regulator was fine but the housing had cracked. Fixed it but not with a replacement.
Shoved a submersible grade hose into the regulator housing under where the crack is and sealed it with a fuel resistant sealing. Not ideal but the bike is running strong, should get me home at least. I'll probably tear this bike down over winter and replace that part and other things.

 

[gbalias]

if you get in there again, replace the hose with corrugated. its better to make the uturn and lasts much much longer.


and you can get it for less than $5, where as the submersible rubber EFI hose runs about $30/ft

 

[WIGGLE2]

IIRC the dodge part is a tad higher pressure...but is a direct fit, seals and all.

if you get in there again, replace the hose with corrugated. its better to make the uturn and lasts much much longer.

Correct on BOTH counts. I do not recall the PSI, but it is more. [up]

 

[WIGGLE2]

400kPa for Chrysler FPR, Stock Buell was 338kPa. You'll have to convert to PSI....I am at work and my notebook is at home.

 

[gbalias]

338kpa = 49psi
400kpa = 58psi

 

[Cooter]

It will run richer if you raise the fuel pressure. You'll get more fuel out of the injector at the same dwell.

There is a formula to calculate exactly how much, but it's more than the computer can compensate for. Will it be a problem? I dunno, maybe your bike will like it[up]