I need some serious help here. I've just changed my fuel filter. I got about 1 km up the road and it just quit, (hard walk back). After pulling it apart and putting it together again I discovered that with the tank in the upright service position, the bike runs. Immediately I thought "Ahhh, a fuel line must get kinked when I lower the tank". No shit, I tried everything to no avail. I even kinked both lines by hand while the tank was up. The bike still ran! As I let go of the lines and carefully lower the tank even half way down, the engine stops! There is about 5 litres of fuel on board. I then thought "I must have the lines crossed around leading from the tank to the pump". But one of them is slightly larger and longer than the other so that couldn't be. Just to make certain, I ask those here who know. There is a fitting on the bottom of the tank and the line from that should go to the bottom inlet on the fuel pump, while the other connects to a standard opening also under the tank
and goes to the top inlet of the fuel pump. Is this correct? I'd be grateful for any assistance with my problem, all I have to get around in is a Ford Festiva. I can nearly run faster than the silly looking thing!
If the tank is raised, the fuel return hose is the one that connects towards the front or top of the fuel tank and the front connector on the pump.
The fuel feed hose connects from the tank outlet closest to the back of the tank and the rear connector on the pump.
You must ensure that the hoses are fitted exactly right and the one with the factory created bend in the end of the hose goes on with the kink facing in the correct direction.
You must also ensure that none of the vacuum hoses in the fuel injector or pump regulator area are getting kinked either because they will stop the regulator from working.
There are some graphics in the 99 busa service manual that is widely distributed amongst members.
Here ya go.
Save you the trouble of finding it.
This is the fuel circulation map from a 99 - 00 busa with external fuel pump.
Click the photo for full size image.
[attachment=4288]
marzman Wrote:I need some serious help here. I've just changed my fuel filter. I got about 1 km up the road and it just quit, (hard walk back). After pulling it apart and putting it together again I discovered that with the tank in the upright service position, the bike runs. Immediately I thought "Ahhh, a fuel line must get kinked when I lower the tank". No shit, I tried everything to no avail. I even kinked both lines by hand while the tank was up. The bike still ran! As I let go of the lines and carefully lower the tank even half way down, the engine stops! There is about 5 litres of fuel on board. I then thought "I must have the lines crossed around leading from the tank to the pump". But one of them is slightly larger and longer than the other so that couldn't be. Just to make certain, I ask those here who know. There is a fitting on the bottom of the tank and the line from that should go to the bottom inlet on the fuel pump, while the other connects to a standard opening also under the tank and goes to the top inlet of the fuel pump. Is this correct? I'd be grateful for any assistance with my problem, all I have to get around in is a Ford Festiva. I can nearly run faster than the silly looking thing!
sounds complicating mate, sorry can't help but good luck
Thank you to you all. I knew you blokes would come up with something. The diagram is greatly appreciated, as is the instruction. I'll put it into effect hopefully with a positive outcome.
We'll fellas, there is no change in the situation. The Festiva is still currently quicker than my bike unfortunately. I've finally found a shop that will look at it, (all the other service centers seem to be booked out well in advance at this minute). I'll let you know what the outcome is for future reference. It's funny, it ran trouble free only a week before on a 3 day trip to Mt Kosiuoscko. I seriously doubt that the trip had anything to do with the problem.
There are a couple of other possibilities in the fuel delivery system.
The bike tip over sensor or the fuel pump relay may be getting a short circuit when the tank goes down.
I'll have a look at those things. Thanks Busgo.
The problem has been solved gang. For those who may encounter a similar problem in future it was the o-ring seals in the pump. They were in poor shape (from being removed once before to change the filter) and the result was a loss in fuel pressure. This is why it would run with the tank up; gravity played a part you see. It was recommended that you use some seal lubricant when changing them so that they sit right before you put the pump back together. That way there will be no problems and my personal recommendation is that one ought to change them when changing the fuel filter anyway; For a couple of dollars it represents true peace of mind. Tally ho chaps!
Glad to hear that you solved your problem.
The service manual does say to replace the seals along with the filter.
I hadn't heard that not doing it would lead to this problem though, so that is a good issue to read.