Fuel pump is not priming - 600RR.net
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post #1 of 41 (permalink) Old 04-04-2010, 10:26 AM Thread Starter
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Fuel pump is not priming

I have a 04 600RR and my problem is that the fuel pump is not turning on like its suppose to. I took the bike apart so i could get it painted and I connected all the wire harness together like almost a simple plug ups.
I checked to see if it was the fuel pump but its not(by pass it and had bought a new fuel pump. Nor its the fuel relay. Or the BAS sensor. Bought an 05 ECU but dont know if that'll work. The KillSwitch is turn on the ON position and its in neutral. I test the brown w/ black wire that is connected to the connector from fuel pump and its not getting power. Would I have to find that specific wire to see where it leads to?? IM stump need some help!!!
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post #2 of 41 (permalink) Old 04-04-2010, 10:33 AM
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Are your turn signals and tail light working?
post #3 of 41 (permalink) Old 04-04-2010, 11:10 AM Thread Starter
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Yes but they aren't connected right now. I had taken them off to get some things powercoated. I know there's nothing major wrong with the bike. I rode the bike before I had taken it apart. ANY SUGGESTIONS??
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post #4 of 41 (permalink) Old 04-04-2010, 11:12 AM
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What was everything you disconnected/removed? That will help narrow down some possibilities.
post #5 of 41 (permalink) Old 04-04-2010, 12:39 PM Thread Starter
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wireharness was taken out so must be in the wireharness somewhere. but i bypass the fuel pump and tried cranking it still no response.
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post #6 of 41 (permalink) Old 04-04-2010, 12:55 PM Thread Starter
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should i find out where the brown wire leads to since its not getting power??
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post #7 of 41 (permalink) Old 04-04-2010, 01:13 PM Thread Starter
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post #8 of 41 (permalink) Old 04-04-2010, 01:15 PM Thread Starter
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can someone tell me what this pluggs up to??
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post #9 of 41 (permalink) Old 04-04-2010, 03:25 PM
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That is a diagnostic plug...

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post #10 of 41 (permalink) Old 04-04-2010, 03:45 PM
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The red plug is the DLC. Don't worry, it shouldn't be plugged into anything.

Why did you remove the wire harness to get things painted?

Are there any codes flashing with the FI light on the dash? if so, what's the sequence of short/long flashes? Since the entire wire harness was removed, you could have a **** load of possible issues. Best to start with the most obvious.

Lift up the fuel tank and disconnect the harness. Hook up a volt meter and check for battery voltage when you turn the ignition to the on position. You should see a spike in voltage for 2-4 seconds before it drops to little to no voltage. If there is voltage present, the fuel pump is bad. If there is no voltage, time for some deeper troubleshooting.

Is the ECM plugged in fully, and the connectors in the correct location?
Is your BAS plugged in and mounted correctly?
Is your engine stop circuit ok? Switch plugged in with no damage and the relay is good?
Is your fuel pump relay working? Can you hear it click when turning the ignition on?
Is the sub fuse for the FI system good?

It will take a while to look through all of that, but the problem will be somewhere within it all.
post #11 of 41 (permalink) Old 04-04-2010, 04:27 PM
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All fuel injectors, Crank and cam position sensors must be plugged in the make the ECU prime the fuel pump...

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post #12 of 41 (permalink) Old 04-04-2010, 11:06 PM Thread Starter
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I hooked the voltage meter to everything from the fuel pump to the the fuel pump relay to the kill switch. Theres two pluggs to the killswitch and I hook the voltage meter to the kill switch. It only read only one plugg but does the other plugg suppose to have power, if so wat is the color code and wat is the voltage meter and is that the right kill switch wires??

also theres no power to the brown wire
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post #13 of 41 (permalink) Old 04-08-2010, 02:19 AM Thread Starter
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IS there suppose to be power to the two wires to the killswitch?? ANyone??
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post #14 of 41 (permalink) Old 04-17-2010, 01:59 PM Thread Starter
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could it be the spark pluggs that makes the fuel pump not prime? but that would mean i have to drop the motor to get to the spark plugg?
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post #15 of 41 (permalink) Old 04-17-2010, 02:34 PM
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No, the spark plugs wont prevent the fuel pump from priming, and you don't have to drop the motor to get to them.
post #16 of 41 (permalink) Old 04-18-2010, 12:06 AM
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www.helminc.com get the service manual and look through the wiring diagram. it will show you what wires will have power and what are grounded.

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post #17 of 41 (permalink) Old 04-18-2010, 08:48 PM
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05-06 ECM is different than the 03-04 ECMs, I'm having this exact same problem, bought new harness and ECM and still my bike aint priming the pump, the ECM controls the pump on/off, if you ground that brown/black wire at the pump relay the pump should come on.
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post #18 of 41 (permalink) Old 04-18-2010, 08:52 PM
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brown/black wire at the pump gose to the gauges for the fuel level indicator
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post #19 of 41 (permalink) Old 05-02-2010, 02:58 PM
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I had the same problem a while back, i simply connected everything as I was putting the bike back together, turn signals and all and the fuel pump turned on when i started the bike up, I guess it thought that something was messed up with the wiring because everything wasnt hooked up so it didnt allow it to turn on.
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post #20 of 41 (permalink) Old 06-16-2010, 11:43 PM Thread Starter
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so i finally took out my spark plugs and they looked fouled and had a bit of oil in it. no spark could that means that it wont prime the fuel pump?
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post #21 of 41 (permalink) Old 06-16-2010, 11:47 PM
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are the grounds hooked up and corrosion free?
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post #22 of 41 (permalink) Old 06-17-2010, 06:50 AM
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so i finally took out my spark plugs and they looked fouled and had a bit of oil in it. no spark could that means that it wont prime the fuel pump?
Fouled plugs wont prevent the fuel pump from priming.
post #23 of 41 (permalink) Old 06-17-2010, 08:33 AM
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I've had issues with my fuel pump sometimes not priming. It first started when I bought the bike but the dealer couldn't replicate the problem so I couldn't get it fixed under warrenty. I finally started throwing parts at it from my own pocket.

It was a defective kill switch. Sometimes it would work, and sometimes it wouldn't. But after replacing the kill switch I've had no issues.
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post #24 of 41 (permalink) Old 06-17-2010, 12:09 PM
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ALWAYS check all grounds if all other obvious symptoms are fine.

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post #25 of 41 (permalink) Old 06-17-2010, 12:31 PM
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I've had issues with my fuel pump sometimes not priming. It first started when I bought the bike but the dealer couldn't replicate the problem so I couldn't get it fixed under warrenty. I finally started throwing parts at it from my own pocket.

It was a defective kill switch. Sometimes it would work, and sometimes it wouldn't. But after replacing the kill switch I've had no issues.
WARRANTY, with two "a's". There is no ******* e in warranty.

WARRANTY.
post #26 of 41 (permalink) Old 06-23-2010, 12:51 AM Thread Starter
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Im going to take my BAS to honda and check to see if it works. How would you know if the killswitch went bad? I think it works but wondering if you could help me understand.
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post #27 of 41 (permalink) Old 06-23-2010, 10:30 AM
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Im going to take my BAS to honda and check to see if it works. How would you know if the killswitch went bad? I think it works but wondering if you could help me understand.
Corossion, or just the contact points getting worn or bent. It's common for kill switches to go bad if used often.
post #28 of 41 (permalink) Old 06-24-2010, 12:35 PM Thread Starter
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it does turn over so it can't bad.
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post #29 of 41 (permalink) Old 06-24-2010, 12:41 PM Thread Starter
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The fuel pump relay which is the the furthest to the the right. I was wondering what is the voltage reading when the (brown and black stripe wire) is prime and when it is not priming?? I know i shouldn't hook the bike to my car so i know im not getting the proper voltage reading.
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post #30 of 41 (permalink) Old 06-24-2010, 03:10 PM
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A bad kill switch will still let the engine crank. It just kills power to the ignition and fuel systems.

The start switch is just a 12v on/off that gives power to the starter motor relay, which then goes to the starter motor, when it's pressed.
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