2009 Bike won’t run after sitting… Fuel related issue.. Help.

[Roadstar_Rob]

I’m the original owner of this 2009 bike.. its got 10k miles on it. It’s been sitting mostly unused for past 2 years.. .I’d start it every few months and would always fire up.. Last fired up was in January of this year. Went out to fire it up and wouldn’t kick over.. Turns over just fine.. .Battery seems all good.. Getting spark at the plugs… I did notice a bit of rust in the tank… I removed the tank.. emptied the old fuel and clean it out as best I could. I have the fuel tank fittting off at the moment (blue tab) and cranking the bike looking for fuel to come out.. I don’t see any fuel coming out of the tank/fuel pump when cranking.. I’m assuming fuel should pulse out of the tank when cranking? Thoughts on the above? I don’t here the fuel pump kick on or pressurize when turning the key.. Any help would be appreciated. Thanks.

[Lug Nut]

Sounds like dead fuel pump....check fuss and relays...your pump is in tank and very exoensive unfortunately.

[Roadstar_Rob]

Thanks Lug.. Is there a specific fuse for fuel pump? I don’t one in the left side fuse box (when sitting on bike). Relay? Thanks much.

[Brad_G]

We had a thread a while back regarding a pump that didn't start when turning on the key. There were other issues with this bike but there might be a few tidbits to take from it. https://www.roadstarclinic.com/forum...ter-deployment

Since the pump isn't pressurizing that would be the first place to start. Do you have a service manual? If not PM me with your email address and I can help there.

While this sounds very simple, I know the bike won't turn over if the kill switch is flipped. But I don't recall if the fuel pump runs or not (I don't think so, but can't say with 100% certainty and the bike isn't nearby to check). If it's turning over but pump isn't running that should rule out the kill switch portion of the circuit. But there are other fuses, relays, and diodes along the way. The service manual helps to point out where some of these are and some troubleshooting steps.

[Roadstar_Rob]

Thanks so much for the assist. [email protected]. I’ll also review the link to that other post.. much appreciated. Rob

[Brad_G]

Message sent. Let me know if everything works.

[Roadstar_Rob]

Update.. The electrical system all checked out.. The fuel pump connection is getting energized for 3 seconds when turning the ignition “on”… so would appear the fuel pump itself is the culprit.. Upon taking it out of the tank it is very dirty and lots of rust in the tank.. Is the pump serviceable whatsoever? Does it even come apart at all? Dealer wants $650 for it so can’t hurt to dig into it if possible. Anyone dig into one before?

[Brad_G]

Well good so see you're getting power through the relay for a few seconds as expected and narrowed it down to the pump. I can't help much with the pump as I've not been into it myself nor seen any posts here regarding that. Looks like you may be the pioneer here so let us know what ends up fixing things. I'll send you a link here shortly with the manual.

[Father Pobasturd]

Too bad it's F. I. If it was carbureted, you could have just thrown that pump away.

[davej]

does anyone know what the normal operating fuel PSI is for a FI bike? When I looked up the OEM fuel pump it appears to cost almost $600. I would be tempted to try a high pressure aftermarket pump like this before I spent $600. this one sounds like it is adjustable up to 125 psi.
https://www.googleadservices.com/pag...gQIARBg&adurl=

[Brad_G]

davej, is there supposed to be a link? But to answer your question, I too wonder if a pump can be substituted if one were creative enough. Here's info from the service manual.

[davej]

there is a link in my post written in red. That pump will proved up to 125 psi and is adjustable and it is $24. I think all that would need to be done is to gut the oem pump so it is just a outlet from the tank. run it into a filter if you want to then to the aux pump then back to the rest of the oem fuel system. Just make sure it is a high flow filter if you use one.

[Brad_G]

davej, funny I see links in some of the previous posts but not yours. (I presume your referring to post #9 in this thread)

[roadiemort]

This is the one in Dave's link.

[Brad_G]

Thanks Mort. Still odd that I don't see the link. I've wondered if you could adapt something like that pump and use an older tank w/petcock on a later FI bike. Gain back some of that capacity lost.

[catnaper2]

Here's one that is listed for the FI Road Star. It is $40 but includes a couple pick-up screens to protect from debris from going to the injectors. It also includes a replacement tank seal for the installation. The brand "Kemso", is a pretty reputable product that makes a wide range of replacement fuel injection pumps injected vehicles. I know several guys with Victorys that have had good luck with them as a replacement pump. Here's the link:

https://www.ebay.com/itm/29430671738...3ABFBM1M7z3upf

Hope this helps.

Steve

[Brad_G]

Wow...$40 is a far cry from $5/600 that's for sure! Thanks for the input Steve, I'm sure it'll be something Rob will be very interested in.

[D-Fresh]

Is the Kemso a direct replacement or a work around?

[Brad_G]

Well the Ebay add uses the same Yamaha part number as online dealers. I wonder if the schematic drawings from dealer parts list has the pump inside a housing?

[Roadstar_Rob]

I just took my pump apart.. the OEM is a Mitsubishi branded “UC-T35” part #.. When you google that number a bunch of different fuel pumps show up… not sure the Kemso is a direct replacement but does appear to be exact same dimensions as the one in the OEM pump…. To clarify there is a motor housing inside the OEM fuel pump.. That is the UC-T35 pump/motor. It appears there are several inexpensive options to replace just the pump motor inside the OEM fuel pump.. exact fit no modification needed…

[Roadstar_Rob]

Here’s one on Amazon for $25.. https://www.amazon.com/DEAL-AUTO-ELE.../dp/B076L9X679

[catnaper2]

The kit is for the Road Star with tank seal included. It shows matching the Yamaha part number, so I'm pretty sure you just swap parts and put back together. That's the way the Victory kits are. You can pull up the Kemso website: https://www.kemsofuelpumps.com/ and give them a call if you have questions. They are in Texas.

[Brad_G]

Roadstar_Rob, if you haven't already, would you mind taking some pics as you go along. I'm curious to see what all is involved in this repair. Thanks!

[Roadstar_Rob]

just ordered the one from Amazon as they had next day delivery option.. Hopeful to have it tomorrow and back in the bike tomorrow evening.. I’ll update this thread on results.. Here are some pics from the disassembly.. The top of the pump assembly is snug fitted onto the pick up tube/o-ring of the pump housing.. It’s on there really tight.. You have to prior very hard and methodically side to side but eventually it slides off.. I thought for sure I was going to snap the plastic but it finally came off.. You can then slide out the actual fuel pump/motor assembly out…. The one on Amazon had very good pictures online and it’ looks absolutely identical. This one..

https://www.amazon.com/HiSport-Motor...maWVyPUExUDlKS VdFTDhLVkJSJmVuY3J5cHRlZElkPUEwOTU0MDA0M1A4WFdXS0J MVk5QTyZlbmNyeXB0ZWRBZElkPUEwNzI2OTExMVc2TVA4SFg4W VRGNCZ3aWRnZXROYW1lPXNwX2F0ZiZhY3Rpb249Y2xpY2tSZWR pcmVjdCZkb05vdExvZ0NsaWNrPXRydWU=

[Brad_G]

This is good info. Thanks for following up with details and pics. Hopefully you're pump goes back together easily and you're on the road riding soon.

[DEEPHATE]

I'm kind of surprised this wasn't common knowledge about replacing the expensive OE FI pump with a cheap aftermarket replacement here amongst the FI crowd here. .

[DEEPHATE]

Is this the first bad one known maybe??

[Brad_G]

Not nearly as many FI bikes in this group compared to carb'd. But this hasn't been something that's come up so it's not widely documented. Rob providing pics and his replacement link (along with the one Steve shared) is going to be helpful in the future for others.