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Discussion Starter #1
I looked for the old thread of mine about fuel pump fail ,could not find it ,

so quick up-date , new walbro pump installed and a fuel filter sytec under the tank ,it is flow rated and seems to be ok , but dyno man said i have big issues with fuel pressure ? It still pulled 175 bhp 92 lbs-ft but down on last years same dyno numbers 5 bhp and 6 lbs-ft of torque ,down. i have since noticed that my fuel return pipe was getting squashed slightly when tank goes back down ,which i think may have been the problem ?
Anyway the bike runs fucking real bad ,i only just managed to get it home last week ,throttle was very on/off ,you had to feather the throttle to just keep it rolling !!
No FI light ,it starts but as soon as you touch the throttle it revs and then cuts out ! could it be the pressure sensor ?
I have re-connected the original ecu (un-plugged PC5 ) no difference ?
Getting pissed off now , i have 2 new tyers to destroy and winter is here :banghead: over £100 for a new pressure sensor !!
 

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map sensor?
a restricted or kinked return line would make it run terrible.
 

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Im not sure what a map sensor has to do with fuel pressure, but if you had it hooked up wrong (like to the tps plug) it could be causing the bike to run poorly or not at all.
 

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FYI the bike doesnt/cant monitor fuel pressure, its done mechanically, and if theres a problem, the ecu doesnt know
 

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Discussion Starter #6
Im not sure what a map sensor has to do with fuel pressure, but if you had it hooked up wrong (like to the tps plug) it could be causing the bike to run poorly or not at all.
No all connectors are where they should be ?

Does anybody know what the symptoms are for a failed or failing pressure sensor ?

I am not very competent when it comes to electrics on newer bikes (FI) !!

it runs so shit i can not even take it to my machanic friend !!!!
 

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Andy, have you removed the suspect pipe and checked it is ok?
Its very easy and ridiculously cheap to change and would at the very least eliminate it.
Are you 100% sure new pump is good and the filter you have used is flow rated at 165+ lph?
Is the exterior Walbro pump below or above the outlet of the fuel tank?
Im suffering a similar cutting out problem since refitting my motor recently and feel your pain. Fortunately I have fault light so can diagnose. I shut the door on it for my sanity back in my garage tomorrow.

Good luck. Just go backwards and eliminate . Its soul destroying but when you solve it you will be happier than a sand boy!
 

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Discussion Starter #8
Andy, have you removed the suspect pipe and checked it is ok?
Its very easy and ridiculously cheap to change and would at the very least eliminate it.
Are you 100% sure new pump is good and the filter you have used is flow rated at 165+ lph?
Is the exterior Walbro pump below or above the outlet of the fuel tank?
Im suffering a similar cutting out problem since refitting my motor recently and feel your pain. Fortunately I have fault light so can diagnose. I shut the door on it for my sanity back in my garage tomorrow.

Good luck. Just go backwards and eliminate . Its soul destroying but when you solve it you will be happier than a sand boy!
Cheers for your comments dave , I also walked away from it saturday i changed the fuel pump relay because it was all green and corroded ,no difference !, i think i will put the whole system back to standard and see what happens !? also my walbro pump is in-tank ,but the filter is now outside the tank (underneath the tank) and it is flow rated sytec re-useable one 200 + lph ,i think the squashed return fuel pipe under the tank caused the high number readings at the dyno ? but it still pulled well and had 175 bhp , but it was not 100 % ,but since the dyno approx 100 miles it has just became worse and now is un-rideable ..... the joys of zx12r ownership :banghead::banghead:
 

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No all connectors are where they should be ?

Does anybody know what the symptoms are for a failed or failing pressure sensor ?

I am not very competent when it comes to electrics on newer bikes (FI) !!

it runs so shit i can not even take it to my machanic friend !!!!


WHAT pressure sensor?
 

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any sensor on the bike can make it act up if its not working.
 

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is there any chance that some crap got in the pressure relief valve if it has your pump will still deliver full flow but low pressure good luck Craig
 

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Discussion Starter #14
is there any chance that some crap got in the pressure relief valve if it has your pump will still deliver full flow but low pressure good luck Craig
the pump has a round proper filter on the in-let end ,and then i have a sytec filter on the out-let end before the fuel reaches the throttle bodies , so i can not see any shit getting through both filters ?
i think like dave said , re-check everything i have done ,i will have another look at it tomorrow ...... very frustrating !!!
 

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As a test bypass both filters and also check the in tank return valve.
You could put a bolt in the tank and the pipe with the valve into a container so you can see fuel is returning and flowing.
My money is on the intank filter ...
You dont need two filters.
Good luck. Let us know :)
 

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Discussion Starter #16
As a test bypass both filters and also check the in tank return valve.
You could put a bolt in the tank and the pipe with the valve into a container so you can see fuel is returning and flowing.
My money is on the intank filter ...
You dont need two filters.
Good luck. Let us know :)
Thanks for your reply dave , i thought you would need a pre-pump filter simular to the original set up ? sock type thing ? would it damage the pump if shit got sucked up into the pump ?

i have a day off tomorrow so i will get stuck in and try to get the fat bitch revving again !!!
 

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Discussion Starter #18
Is your external filter a one way jobbie?
yes it has a arrow for direction , and it is going the right way ! both times i have taken it off it has been full of fuel , and also no signs of dirt at all .

with this set up it was running ok , but the dyno chap said something is wrong with the fuel pressure ,he said the PC V will deal with it ?
so 100 miles later it is running really bad ,if you touch the throttle it just dies, i only just managed to get it home the other day , what i am thinking is maybe i have damaged something ? one of the sensors by running it like this ?
if i only need one filter which one should i keep pre-pump filter or in-line filter under the tank , what do you lads reckon ,or know ?
 

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why dont you verify fuel pressure???
 
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