still have fuel pump problems

exharley · 05-18-2015, 01:16 PM

05 1600 Nomad , with FI,
My bike will start, run for about 5 seconds and then shut off , it will immediately start up and run for 5 seconds and then shut off. It does this repeatedly. Starts right back up. I would think if the fuel pump was the problem that it wouldn't start at all . I changed out the DFI relay and it's no difference.
I've got a new fuel pump but thought I'd ask the question before I dove in on it. Is there a fuel pressure sensor in there?
Jim

**HwyRider** · 05-18-2015, 01:43 PM

Love the Avitar.

**canuckrider** · 05-18-2015, 01:54 PM

Have you had the tank off and pulled the fuel pump?

There is an internal fuel filter in there as well as a fine screen on the intake side of the pump. I had issues with the bike not accelerating and just bogging down if I applied too much throttle. Pulled the filter and found it blocked with a lot of debris and crud. I can only assume that it was from getting some dirty fuel somewhere.

Maybe you're just getting enough fuel for it to fire up and run a bit but not enough to run continuously??

exharley · 05-18-2015, 06:59 PM

Found the problem and fixed it. Took the tank off and pulled the pump. Replaced it with a fuel pump from Fuel Pump Factory. The screen on the other pump was clean, no clogs. Fired it up and it killed 3 times cause the pump was empty and the lines too. Once it filled then it fired up and runs like brand new.
The pump only cost $50 and since I did the work myself I reckon I saved over $600 as the dealer would probly bought the whole assy and installed it.
Thanks fellers
Jim

redbrd · 05-18-2015, 08:45 PM

$50 I heard those fuel pumps were around $800, I guess that's from the Kawasaki dealer

**Rasta** · 05-18-2015, 09:43 PM

I am sure the $50 pump was an eBay or so pump. At the dealer you have to buy the whole assembly. Glad to hear that took care of the problem.

exharley · 05-18-2015, 09:54 PM

As I said , the fuel pump can be gotten from Fuel Pump Factory, I don't know if they are on ebay or not, might be. They are a wholesale dealer, for CNTand Walbro fuel pumps, motorcycle, Auto, marine and ATV.
I got the site from a member on my Kawasaki site.
WWW.FUELPUMPFACTORY.COM

**Rasta** · 05-18-2015, 10:00 PM

That's a nice link you have for fuel pumps. Yes you can find them on eBay as well.

exharley · 05-18-2015, 11:17 PM

Tell ya what.....shows how old I getting.
I got the information from a feller on this site and it was an ebay item he told me about. I don't know how I get anything fixed with old timers disease.

roads1 · 05-20-2015, 10:08 PM

I have had similar problems with the fuel pump. However, mine is not the actual pump or filter, but a small rubber bushing that connects the pump to the pressure regulator. The bushing split (alcohol in the fuel) and that part is not sold unless you buy the whole fuel pump assembly from Kawasaki.
Checked with Rubber specialty wholesalers, auto parts dealers, even plumbers. There has got to be a 15 cm long and id 10 cm ribbed rubber bushing. It is a push fit so no clamps.

Any suggestions? I cannot be the only one with this dilemma.

exharley · 05-21-2015, 01:33 AM

Looks like I spoke too soon myself.
It seemed to run good for about 90 Min and then started the same symptoms all over again.
So far I replaced the pump, the DFI relay and now I have ordered the relay just to the left of the DFI which is some kind of companion of the DFI. We'll see what's up once it gets here.
I sure don't want to take the fuel pump apart again but I will if I have to.

**Rasta** · 05-23-2015, 03:24 PM

That sucks. Hope you get it solved

**cnc** · 05-23-2015, 09:49 PM

Quote:

Originally Posted by roads1

I have had similar problems with the fuel pump. However, mine is not the actual pump or filter, but a small rubber bushing that connects the pump to the pressure regulator. The bushing split (alcohol in the fuel) and that part is not sold unless you buy the whole fuel pump assembly from Kawasaki.
Checked with Rubber specialty wholesalers, auto parts dealers, even plumbers. There has got to be a 15 cm long and id 10 cm ribbed rubber bushing. It is a push fit so no clamps.

Any suggestions? I cannot be the only one with this dilemma.

Did you mean milimeters? 15cm= 5 29/32 in and 10cm= 3 15/16 in
Pretty big bushing. Is it actually rubber or a hard plastic. A pick would be useful.

roads1 · 05-28-2015, 01:52 AM

I ended up buying an entire fuel pump assembly from a breaker yard. The unit arrived and the mechanic(I know my limitations) should have it up and running tomorrow.

I tried to find a replacement O ring and was unable. made a part that blew out after 5 minutes idling.

Really trying to avoid a factory new pump unit.

oldmansalt · 05-28-2015, 08:30 PM

The O ring is not included with the new pump. A dealer should have it or can order the o ring. Its about $15.00.

05-18-2015, 01:16 PM	#1
exharley Member Join Date: Mar 2012 Location: Culleoka, Tn Posts: 136	still have fuel pump problems 05 1600 Nomad , with FI, My bike will start, run for about 5 seconds and then shut off , it will immediately start up and run for 5 seconds and then shut off. It does this repeatedly. Starts right back up. I would think if the fuel pump was the problem that it wouldn't start at all . I changed out the DFI relay and it's no difference. I've got a new fuel pump but thought I'd ask the question before I dove in on it. Is there a fuel pressure sensor in there? Jim __________________ Life is too short to dance with ugly women. Login or Register to Remove Ads
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05-18-2015, 01:43 PM	#2
HwyRider Join Date: Jun 2013 Location: South Shore, MA Posts: 4,629	Love the Avitar. __________________ VBA # 02424 VROC # 35971 2010 Nomad 1700 Metallic Diablo Black/Metallic Titanium
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05-18-2015, 01:54 PM	#3
canuckrider Join Date: Jun 2010 Location: Okotoks, AB, Canada Posts: 1,088	Have you had the tank off and pulled the fuel pump? There is an internal fuel filter in there as well as a fine screen on the intake side of the pump. I had issues with the bike not accelerating and just bogging down if I applied too much throttle. Pulled the filter and found it blocked with a lot of debris and crud. I can only assume that it was from getting some dirty fuel somewhere. Maybe you're just getting enough fuel for it to fire up and run a bit but not enough to run continuously?? __________________ "Sun on my face, wind in my hair, sound of my bike in my ears and peace in my soul..." VBA Member #01514 2008 "Ultra" Nomad 1600, Candy Plasma Blue
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05-18-2015, 06:59 PM	#4
exharley Member Join Date: Mar 2012 Location: Culleoka, Tn Posts: 136	Found the problem and fixed it. Took the tank off and pulled the pump. Replaced it with a fuel pump from Fuel Pump Factory. The screen on the other pump was clean, no clogs. Fired it up and it killed 3 times cause the pump was empty and the lines too. Once it filled then it fired up and runs like brand new. The pump only cost $50 and since I did the work myself I reckon I saved over $600 as the dealer would probly bought the whole assy and installed it. Thanks fellers Jim __________________ Life is too short to dance with ugly women.
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05-18-2015, 08:45 PM	#5
redbrd Member Join Date: Oct 2014 Location: Pitt meadows BC Canada Posts: 75	$50 I heard those fuel pumps were around $800, I guess that's from the Kawasaki dealer __________________ What doesn't kill you makes you stronger, 2004 nomad/ 2006 KLX 250. Login or Register to Remove Ads
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05-18-2015, 09:43 PM	#6
Rasta Join Date: Sep 2011 Location: Ankeny Iowa Posts: 3,694	I am sure the $50 pump was an eBay or so pump. At the dealer you have to buy the whole assembly. Glad to hear that took care of the problem. __________________ VROC#34321 VBA#01867 2012 NCR Rally Savanna. IL. 2013 National Rally Estes Park, CO 2014 NC/SC Rally in the Ozarks, Mountain View AR 2014 NE US/Eastern Canada Rally,Lincoln NH 2015 VBA/VRA Eureka Springs AR 2015 Antlers Rally, Antlers OK. 2016 SCR Rally Salem MO. 2016 NCR Rally Hillsboro WI 2017 Eureka Springs AR 2017 National Rally Lake George NY 2004 Blue and Silver 1500 Nomad(RIP 9-26-19) 2000 Red and Silver 1500 Nomad 2012 Pearl White 1700 Voyager
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05-18-2015, 09:54 PM	#7
exharley Member Join Date: Mar 2012 Location: Culleoka, Tn Posts: 136	As I said , the fuel pump can be gotten from Fuel Pump Factory, I don't know if they are on ebay or not, might be. They are a wholesale dealer, for CNTand Walbro fuel pumps, motorcycle, Auto, marine and ATV. I got the site from a member on my Kawasaki site. WWW.FUELPUMPFACTORY.COM __________________ Life is too short to dance with ugly women.
	0

05-18-2015, 10:00 PM	#8
Rasta Join Date: Sep 2011 Location: Ankeny Iowa Posts: 3,694	That's a nice link you have for fuel pumps. Yes you can find them on eBay as well. __________________ VROC#34321 VBA#01867 2012 NCR Rally Savanna. IL. 2013 National Rally Estes Park, CO 2014 NC/SC Rally in the Ozarks, Mountain View AR 2014 NE US/Eastern Canada Rally,Lincoln NH 2015 VBA/VRA Eureka Springs AR 2015 Antlers Rally, Antlers OK. 2016 SCR Rally Salem MO. 2016 NCR Rally Hillsboro WI 2017 Eureka Springs AR 2017 National Rally Lake George NY 2004 Blue and Silver 1500 Nomad(RIP 9-26-19) 2000 Red and Silver 1500 Nomad 2012 Pearl White 1700 Voyager
	0

05-18-2015, 11:17 PM	#9
exharley Member Join Date: Mar 2012 Location: Culleoka, Tn Posts: 136	Tell ya what.....shows how old I getting. I got the information from a feller on this site and it was an ebay item he told me about. I don't know how I get anything fixed with old timers disease. __________________ Life is too short to dance with ugly women.
	0

05-20-2015, 10:08 PM	#10
roads1 Member Join Date: Feb 2008 Location: Pensacola, Florida Posts: 76	I have had similar problems with the fuel pump. However, mine is not the actual pump or filter, but a small rubber bushing that connects the pump to the pressure regulator. The bushing split (alcohol in the fuel) and that part is not sold unless you buy the whole fuel pump assembly from Kawasaki. Checked with Rubber specialty wholesalers, auto parts dealers, even plumbers. There has got to be a 15 cm long and id 10 cm ribbed rubber bushing. It is a push fit so no clamps. Any suggestions? I cannot be the only one with this dilemma.
	0

05-21-2015, 01:33 AM	#11
exharley Member Join Date: Mar 2012 Location: Culleoka, Tn Posts: 136	Looks like I spoke too soon myself. It seemed to run good for about 90 Min and then started the same symptoms all over again. So far I replaced the pump, the DFI relay and now I have ordered the relay just to the left of the DFI which is some kind of companion of the DFI. We'll see what's up once it gets here. I sure don't want to take the fuel pump apart again but I will if I have to. __________________ Life is too short to dance with ugly women.
	0

05-23-2015, 03:24 PM	#12
Rasta Join Date: Sep 2011 Location: Ankeny Iowa Posts: 3,694	That sucks. Hope you get it solved __________________ VROC#34321 VBA#01867 2012 NCR Rally Savanna. IL. 2013 National Rally Estes Park, CO 2014 NC/SC Rally in the Ozarks, Mountain View AR 2014 NE US/Eastern Canada Rally,Lincoln NH 2015 VBA/VRA Eureka Springs AR 2015 Antlers Rally, Antlers OK. 2016 SCR Rally Salem MO. 2016 NCR Rally Hillsboro WI 2017 Eureka Springs AR 2017 National Rally Lake George NY 2004 Blue and Silver 1500 Nomad(RIP 9-26-19) 2000 Red and Silver 1500 Nomad 2012 Pearl White 1700 Voyager
	0

05-28-2015, 01:52 AM	#14
roads1 Member Join Date: Feb 2008 Location: Pensacola, Florida Posts: 76	I ended up buying an entire fuel pump assembly from a breaker yard. The unit arrived and the mechanic(I know my limitations) should have it up and running tomorrow. I tried to find a replacement O ring and was unable. made a part that blew out after 5 minutes idling. Really trying to avoid a factory new pump unit.
	0

05-28-2015, 08:30 PM	#15
oldmansalt Jr. Member Join Date: Apr 2014 Location: San Tan Valley, AZ. Posts: 10	The O ring is not included with the new pump. A dealer should have it or can order the o ring. Its about $15.00.
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