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Problem cbr 600 2004 (SOLVED)

389 Views 22 Replies 3 Participants Last post by  Marc9
Hi, i have a problem with my cbr 600 2004, the bike works great until 8000 rpm, then it stuck, looks like a limitator, at full throttle the power commander 3 usb doesn't flash all lights, but it stop at second last, i try to calibrate the sensor accelerate in power commander program but nothing, result 100 % at full gas but the led not full flash. I' m desperate with this bike, i only want to destroy it.
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Don't be angry with the bike. It's probably the fuel pump. Do you have a service manual? You'll need to disconnect the fuel line from the fuel rail and then catch the fuel in a bucket to measure. Put a jumper wire on the fuel cut relay to run the pump for 10 seconds. You should have about 6.5 ozs (US).

You'll also need to test the pressure of the fuel pump. For this test you 'll need a 100 psi fuel pressure test kit. Install the gauge inline with the fuel rail and check for 50 psi of pump pressure.

If it fails either test, rebuild the fuel pump assembly. You can only replace the fuel pump strainer (suction before the pump), the fuel pump motor, and the pressure regulator. You cannot replace the final fuel filter which is not serviceable. When you are finished, run both pressure and flow tests AGAIN to confirm the pump is working correctly.

Pressure regulator - You can either soak the old one in carburetor cleaner over night or some other solvent. But make sure it's clean. You can also buy a new one with some of the pump kits. Whatever you decide make sure you run a zip-tie around the pressure regulator and strap it to the pump assembly. This prevents the pressure regulator from coming back out and causing a dangerous low pressure scenario you probably already have.

Clean your fuel system now! While you have it down inspect the tank and clean your injectors.

The PC3 - The lights you see are just showing you the rpm signals from the ECU. It probably has nothing to do with the issue. However, you can disconnect the PC3 temporarily without having to remove it. The hardest one is the TPS signal wire. You can use your GF or a small child with small hands to disconnect the PIN connector.
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Don't ride the bike until you fix this issue. If it is starving the bike of fuel you WILL burn a hole in a piston eventually.
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Thank you, i appreciate your help, tomorrow i will disassembly the fuel pump and replace with new one.
Thank you, i appreciate your help, tomorrow i will disassembly the fuel pump and replace with new one.
Why replace something that may not be the problem? Solve the mystery first by testing the current pump. You need to confirm what the problem actually is before introducing more variables with new parts. You will use the same pressure kit and methods on the new pump also. Otherwise, you have no idea what the actual problem is.

Don't use guess work. It only cost more time and money.
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Don't replace fuel pump until you measure flow and pressure!!!

1. Fuel-filtre may be clogged. Pumping fuel from new pump into clogged filtre will still result in low flow

2. FPR may be dislodged. Will result in petrol escaping and falling back into tank

3. FPR may be defective, resulting in low-pressure at rail.

If you want to just guess and randomly swap perfectly-working parts with brand-new perfectly working parts, then you must replace entire fuel-pump assembly to luckily catch those items above that has nothing to do with fuel pump. Only get brand-new factory OEM pump assembly #16700-MEE-013 from authorised Honda dealer so you know it works. No use replacing with lower-quality or defective part.

from later gen bike, but same idea:

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Thank you to all for support, i bring the bike to mechanical this morning, he say, after take misurations, that fuel pump is ok, flow fuel ok, injectors ok, now i'm very desperate..... neither he know where is the problem
Still not good enough. You need to get actual numbers measured for your bike. Doesn't matter if you measured it or mechanic. I wouldn't trust any mechanic any further than I can throw them!
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He say me only that pump is good, unfortunately i don't have the tools for self measured, the last chance is change the full group pump, otherwise i can't find the problem, i'm not able to do...
He say me only that pump is good, unfortunately i don't have the tools for self measured, the last chance is change the full group pump, otherwise i can't find the problem, i'm not able to do...
Yes you can. It only takes a few tools to test fuel pump flow and none of them are specialty tools. A fuel pressure gauge can also be rented from some local auto parts stores. Check around.

Unless you have plenty of money stay away from "mechanics".

Still not good enough. You need to get actual numbers measured for your bike. Doesn't matter if you measured it or mechanic. I wouldn't trust any mechanic any further than I
can throw them!
Especially those who don't give you specific information, like pump pressure and flow volume over time. If he didn't record those #'s then he didn't test anything.
He say me only that pump is good, unfortunately i don't have the tools for self measured, the last chance is change the full group pump, otherwise i can't find the problem, i'm not able to do...
You can do volume-flow test easily. No special tools needed. No quick-release fitting on yours, but not that difficult to unbolt fuel-hose from fuel-rail.

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Whit these Instructions i see the flow at minimum rpm, the problem is a 8000 rpm, anyway i test as soon as possible, if the values is correct, what could be the next step ? Thanks dannoxy for the help
Pump provides fixed flow-amount. It doesn't know anything about engine's RPM. The flow-rate number you measure is for maximum consumption at 15000rpm. If not sufficient, engine will work at low-RPM but not at high-RPM. Good pump will actually flow about twice number shown in test.
But i see the gauge still attached in my bike, i do not trust the mechanical, but he has all positive reviews true, he is a professional, he won't buy new p if he say me the pump work fine, where is the problem ????
But i see the gauge still attached in my bike, i do not trust the mechanical, but he has all positive reviews true, he is a professional, he won't buy new p if he say me the pump work fine, where is the problem ????
The only way for your mechanic to KNOW whether the pump is defective is to test and record the flow volume and the fuel rail pressure. If he didn't, he's just guessing like you. Either it tests good or it fails. This is not open to opinion. It's based on factual test data. Data that you haven't been provided by your mechanic. You cannot make an educated decision without this test data.
I take the bike tomorrrow because he is a fully idiot, i order new gauge for misuration, but i need your help, I completely trust you for repair bike step by step.
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All you need is a few hand tools, a fuel pressure gauge kit, and a couple of hours to diagnose this issue. Honestly, if it were my bike I would order the new fuel pump motor kit and rebuild the fuel pump unit regardless. If it's not the problem now it soon will be.

This fuel pump kit actually comes with Quantum's tank gasket which needs to be replaced. I bought a Honda OEM gasket but this one might work also. It also includes a new pressure regulator.
fuel pump kit

This kit has a 2 PIN connector for the motor but our year model do not have a PIN connector. So you will need to solder these to the OEM connections. Do not use any other method. Solder them.

Also, when you install the new pressure regulator put a zip-tie around the filter housing and the PR so it cannot pop back out. Extra safety measure.
I have buying new fuel pump group "quantum", now reach the 11000 rpm instead 8000, without power commander 3 go better, the problem is at full throttle, if I release at 80 % it goes up more, if i open full gas stuck completely.
The bike has full exaust mivv, sport filter.
Ok, this confirms fuel-flow problem, not with fuel-pump. Do volume-flow test and get some numbers before wasting more money on replacing perfectly-working parts with brand-new perfectly-working parts.



DO NOT ride bike anymore until you do this test!! You are risking blowing hole in pistons from lean mixtures due to lack of fuel!
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