update - fuel pump problem ...FIXED.....wheeewww

[myssrhl]

s2r1000 .......keeps cutting off ---- fuel pump......

was intermittent now pretty much terminal.....have  done all the tests even the 30 to 87 on the relay still no pump action...

has  or does anyone have the trick to just bypass the fuel level sensor as i have seen several on this board have the same problem and it be this sensor.....can we just either cut the wires out for the sensor or connect them??

i think this would be a good test.......

[ducpainter]

Short answer is you can't bypass it.

Check for voltage at the wires leading to the sender. (I believe the fuel pump are the red and black wires)

If you have voltage there it could be a bad wire in the sender or a bad pump.

You will have to remove the pump and check voltage at that connector to find out.

[myssrhl]

OK..... pump not running.... shut me down several times over the last few weeks...then finally no go at all......so yesterday  I tilt the tank up still no pumpage.....

I leave the wiring connected remove the pump and while holding pump in my hand ....turn the key ............buzzzzz  Pump Works...

Back in tank pump works.... but for how long?

Have seen others say a bad fuel level sensor can it just be removed is it normally open

Any thoughts??

Thanx

[Armor]

Why do you think there is a problem with your fuel pump?  The fuel level sensor should have no effect on the pump.  Mine is disconnected.

[Drunken Monkey]

^^^^ What he said.

At least on my 01 900 there's no connection (ha ha) between the fuel level sensor and the fuel pump at all.

In fact, the only thing the sensor does is power the "low fuel" light on the dashboard.

[myssrhl]

Got -it .....was the red fuel pump wire going thru the fuel pump assembly....S2R1000

Found that I could wiggle the red wire on the tank side of the pump assembly and get pumpage...

Dug out the epoxy filling / potting and all of a sudden the red wire just fell out...was never soldered into the coupling correctly......Thus I got the trusty solder iron heated up the coupling ...pushed the red wire in and BAMMMMM fixed.......could not pull it out....

Awesome as this has been haunting me for months and finally went into total failure.......Jezzzzz

Pain in the arse.......

[vossy]

good work

[ridingrabbit]

I had the same issue and I posted about it some time back (Topic: Fuel pump issue ). good to here you found that sneaky gremlin

[myssrhl]

the same young Slavic child must have soldered yours and mine......yeah the blob of solder on the end of the wire indicated it had never been inserted into the wire terminal, just sitting on it when they potted it......

There was enough of a solder blob on the end of the wire I just heated the terminal and pushed the wire in which melted the blob....

Simply to fix just a making the beast with two backs'er...to finally locate...

[ridingrabbit]

I used a gasoline resistant epoxy ( actly. caswells gas tank liner epoxy!) to encase the wires, holding up well. 

[iltl32]

I know I'm resurrecting an old thread, here, but a lot of people are having this problem and I'd like to clarify a few things if you don't mind:

1. How did you dig out the old epoxy?  Did this damage any of the wires?
2. Did you disassemble (AKA remove the black plastic cover) from the flange?  If so, aren't the little metal clips holding it together one-time use?  Where did you find replacements?
3. There's a terminal inside the epoxy?  I assumed the wire just ran straight though?

Thanks.

[scaramanga]

if you carefully remove the little clips with a small screwdriver they will be reusable by hammering them flat again.

[ODrides]

Check this other thread ("S2r1k problems") for pics and description of repair for this problem: http://www.ducatimonsterforum.org/index.php?topic=60065.0