Fuel pump on a TE 610

[Straatkat]

My bike has left me stranded  3 times now, every time when I ride 50+ kms the bike cuts out and dies. When I turn the ignition on the fuel pump does not prime. Then I have to make the dreaded call to be collected with the bakkie..... then the next day it starts right up like nothing happened. Due to work pressure I have left it for a while, but need to get my Husky fixed as a Swazi Hardcore ride is looming in a weeks time.
Yesterday I took the tank off to free up the electrical connector of the fuel pump that was tie wrapped to the frame under the tank. The idea is to ride untill it cuts out and then disconnect the fuel pump plug and check for power to the pump. If no power at the plug the fault lies elsewhere. If there is power the pump needs replacement. To prepare for this eventuality I purchased a Bosch universal pump which I will have to make fit as it is quite a bit larger than the original made in China fuel pump. My thinking is that I will also buy a fuel injection filter and replace that as well. The original piping that can be seen in the pic seems high quality as these pipes live inside the tank and is always submerged in fuel. Where am I going to get some pipe that can do that?  Most of the pipe that I have seen for sale ar spares shops are rather crappy.
Can I use hose clamps or is the fuel pressure too high? The original pipes have those moerava strong crimped fittings.
I realise that it might not be the pump and untill I do the test ride wont know for sure, but changing the pump to an universally available (Midas R550) unit that is affordable seems a good upgrade.

[alanB]

If you use high quality clamps and fuel hose that is intended to be submerged in the tank I don't think you will have any issues personally.

[Xpat]

I'm probably just misunderstanding you, but why can't you just use all the original pipes and connectors? Is it because the fuel pump is bigger and you need to make them shorter?

As you know I have fitted the same pump on my 630 and I have used all the original fittings and connectors. The only difference is that I have big Safari tank, so I didn't have problem with space.

[Straatkat]

The filter I got is a bit larger than the plastic original one, but is a steel one, think it will fit in the tank, but that nice ribbed pipe is too small (even if I could get it off) diameter wise to fit the new pump. The Bosch pump I got is widely available, even Goldwagen has an identical one for  only R375.
Maybe I should try a hydraulic shop for the right pipe. The replacement pump operates at 3.88 bar. Does anyone know if that is in the ballpark for what we need?

[M3X3Z3]

These guys are nicely geared for your kind of problem: http://www.fuelperformance.co.za/
Fast and efficient too.

[Straatkat]

Thanks a lot M3X3Z3. And they have a reseller in Krugersdorp. Really appreciate it. Will call them tomorrow.

[Straatkat]

Well I did a 120+km ride today and the bike ran faultlessly, had my multimeter and tools with me to get to the bottom of this thing, but it just would not break down, no matter how hard I rode it. It was one of the only occasions in my life that I actually wanted the bike to break down.....so I am no further with my fault finding. I really don't want it doing a number on me in Swaziland! Maybe removing and replacing the fuel pump or maybe the wiring have done something so that it now runs perfectly....what to do next?

[Kenzogs]

I had a similar problem on my TE310. The bike would run for a while before cutting out or it would just not start. Because it was getting no fuel I thought it was the pump. I stripped it out and connected 12V across it and it always worked so I had to look somewhere else. Eventually I found the relay that controls the fuel pump was faulty - replacing it cured the problem.

[Straatkat]

Thanks Kenzogs, I will look into that.

[M3X3Z3]

In your case I would carry a spare fuel pump, I have had mine give in.

Also I could not see from your photies, but sometimes the actual pump eases out past the two plastic hook clips on it's plastic housing. Make sure the pump is tie wrapped tightly in place:
http://www.cafehusky.com/threads/fi-fuel-pump-mod.3036/

[blazes]

In your case I would carry a spare fuel pump, I have had mine give in.

Also I could not see from your photies, but sometimes the actual pump eases out past the two plastic hook clips on it's plastic housing. Make sure the pump is tie wrapped tightly in place:
http://www.cafehusky.com/threads/fi-fuel-pump-mod.3036/

I keep a new spare pump as well as the TP sensor at hand and a small back up battery when doing long trips should I need them.

Yep that pump needs to be cable tied into place or it moves up horizontal and sucks air --

[Straatkat]

I found some of the correct piping for the pump mod and will assemble it and carry it along, also got a spare relay just to be sure I am prepared for every eventuality. Will also remove the tank again and go over all the wiring connectors and make sure they are all sound and not corroded. At least I will have a fighting chance to get it going should the problem rear it's ugly head

[Straatkat]

Carried all the extra spares and my bike ran like clockwork all week-end. Did some really gnarly bits in Swazi in near 40 deg heat with no problems. I am putting my money on a faulty relay, I noticed under the L/H sidecover sits 3 relays and they are directly above the exhaust, so I made a heat shield that I rivited to the existing heat shield to better protect the relays from heat, and I swopped them around.

[stevovo]

Carried all the extra spares and my bike ran like clockwork all week-end. Did some really gnarly bits in Swazi in near 40 deg heat with no problems. I am putting my money on a faulty relay, I noticed under the L/H sidecover sits 3 relays and they are directly above the exhaust, so I made a heat shield that I rivited to the existing heat shield to better protect the relays from heat, and I swopped them around.

hey Straatkat

Turns out I'm having the same issue with my TE 610 with my fuel pump only turning when hard wired directly and am thinking possible relay problem. Do you perhaps know which of the 3 relays controls the pump please? And do you recall where you got the replacement relay? See what you mean about being right above the exhaust - a perfect place to fry them! 

[TK]

Carried all the extra spares and my bike ran like clockwork all week-end. Did some really gnarly bits in Swazi in near 40 deg heat with no problems. I am putting my money on a faulty relay, I noticed under the L/H sidecover sits 3 relays and they are directly above the exhaust, so I made a heat shield that I rivited to the existing heat shield to better protect the relays from heat, and I swopped them around.

hey Straatkat

Turns out I'm having the same issue with my TE 610 with my fuel pump only turning when hard wired directly and am thinking possible relay problem. Do you perhaps know which of the 3 relays controls the pump please? And do you recall where you got the replacement relay? See what you mean about being right above the exhaust - a perfect place to fry them! 

May even have a relay for you. You could just have dirty contacts on the relay though.