X1 Fuel pump sudden death? Please help with diagnostics!

[maelstromwar]

The bike died in second gear in the parking lot of a grocery store. Started her up getting ready to leave - she ran long enough for me to don the helmet, pull out in first, shift to second and then a permanent stall. This leads me to believe it was running on whatever fuel was remaining in the lines.

I spent several hours stranded trying to make sense of what may be going on. Bike turns over, all the electrics work, plugs have spark, but she just will not fire. It made sense for the issue to be one of fuel delivery so I decided to test the idea by spraying starter fluid (ether) onto the air filter and then cranking over... started right up and ran till the ether evaporated.

Fuel is not being delivered by the EFI

I notice now that when I turn the ignition the bike no longer makes the 2-3 second priming buzz of the fuel lines being pressurized, which makes me wonder if the fuel pump has just crapped out.

Is this a logical conclusion? Does that even happen? Are fuel pumps in general known to experience sudden death? How can I test this idea without spending hundreds of dollars at a dealership?

Thanks in advance for any help!

 

[williegoat]

You have probably tried this but,
1. check the fuses
2. check the connector
3. apply power directly at the connector
4. remove the pump for inspection

 

[maelstromwar]

Checked the fuses. Are there more than just what's under the seat? I'm ashamed to admit that I can't find the fuel pump on my bike. Where exactly is it? Under the tank?

Is the part pictured here just the fuel filter? As far as I can see this is the only bit between the fuel tank and the injectors:

Is this the correct replacement part? I haven't seen anything on this bike that resembles the picture...

http://www.buellparts.net/content-product_info/product_id-2828/lightning_x1_fuel_pump.html

 

[williegoat]

Your fuel pump is in your tank. Follow the fuel line back and up from the filter. Their will be an electrical connector for the pump near there. You must take the tank off to remove the pump. (I guess you don't have to remove the tank, but unless you have very small hands, it sure would be easier)

 

[williegoat]

Also, have you checked for trouble codes? Bank Angle Sensor? Side Stand Switch?

 

[Jramsey]

http://www.fuel-pumps.net/521.html

 

[fluffypancakes]

Mine failed on me too. It's a common Walbro pump found on V6 mustangs. Easy and cheap to get at your local parts store.

 

[maelstromwar]

Thank you all!

williegoat: my bike doesn't have a side stand switch. Don't know how to check the bank angle sensor. The fact that it fires with starter fluid points to a fuel delivery issue.

Just now tested the fuel pump using a voltmeter and direct power (and blew the 20A ignition fuse in the process) and it's confirmed dead. At first I separated the connection and then reconnected the fuel pump to see if that was the issue, the pump gave a last ditch weak sounding prime and then promptly stopped. The bike fired on what the pump managed to put into the lines but since the pump was done she died once fuel ran out.

Jramsey: thanks for saving me a ton of money!

Ordered the new pump. How do I go about replacing the old one? Is the process as intuitive as it seems?

Drain the tank
Remove fuel cap assembly
Unbolt pump from outside of tank
Reach in and pull out old pump
Replace fuel filter at mouth of pump
Install new pump in tank
Seal and bolt in new pump from outside of tank
Reassemble
Ride?

Thanks again,
Roman

 

[Jramsey]

Here's a pic of the pump/regulator assembly,

The fuel outlet fitting is 13/16"
The nut on the wiring fitting is 15/16", the brass fitting this nut fits on may try to unscrew out of the pump base when loosening the nut, if it does you will have to hold it with a 1-1/16" wrench, pain to fish that long wrench inside the tank while trying to see inside the tank with a flash light.

Once removed from the tank remove the 2 wires from the pump,pry the pumps band clamp loose and remove/pry pump from the base.


Replacement O-rings and rubber flat washers needed should be available from local auto parts store.

 

[x1_rydr]

You'll need to purchase a new Retaining Clamp that holds the fuel pump to the housing, since you'll have to cut off the existing one to remove the fuel pump.

You may need to replace the rubber washers under the Fuel Fitting nut and the Wiring Harness nut.

The manual calls for the use of Hylomar (it's a sealant) when reinstalling the fuel cap assembly onto the fuel tank. I ordered a tube through O'Reilly's Auto Parts.

Good luck.

 

[maelstromwar]

Thanks for the walkthrough fellas. Will report back when pump is delivered.

 

[maelstromwar]

Fuel pump replaced, started right up! Thanks for the help everyone!

This morning saw a minor fuel drip from around the 15/16 fitting. Does anyone know what size those rubber gaskets on the inside of the tank are?

 

[Jramsey]

Inside is a neoprene washer 5/8" ID x 1"OD x 3/32" thick, outside is a metal washer with a embedded O-ring I don't really know what its called, maybe a sealwasher.

Fuel outlet is a 3/8" x 7/8" neoprene washer on the inside and a R-09 O-ring out side.

 

[maelstromwar]

Thank you Jramsey.

 

[robporter9]

I orderd a fuel pump from american sport bike ,not here yet and has cost me $377 with shipping. Mine 01. S3 runs out of gas if pushed hard or riden faster than. 68mph for a long distance. Hope I was right , would have bEen easier if it just quit like yours. For that price I wonder if it comes with everything needed or will I have to find the rubber gaskets and rings.