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Old 08-01-2013, 04:43 PM   #1
erappaport OP
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Fuel Pump Relay?

2003/4 950A Cranks but won't fire...

Rolling my 950A out after off-season storage, put away for 7-8 months the way I have in the past without issues- End-of-year oil change, Star-tron in the fuel, heated storage, etc..

Over the winter I pulled the generator cover to change the balance shaft seal, but did no other work. Now the bike cranks right over, but gives no hint of firing. I've got lights, horn and instruments, but what I don't hear like I usually do is the fuel pump when I turn the key. I've got current at the fuse bus, a good fuse, but don't appear to be getting juice at the pump.

I'm wondering about the fuel pump relay, which is downstream of the fuse on the wiring diagram, and connected to the ECU. Can someone tell me where it actually is on the bike, and/or if they've ever heard of it faltering?

Also happy to hear other thoughts, like why the ECU might not be calling for fuel, or why I might be barking up the wrong tree altogether. I know it could be lacking spark instead of fuel, but I thought I'd start with the latter since the pump is being so quiet.
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Old 08-02-2013, 09:56 AM   #2
RedRupert
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The fuel pump relay is behind the left-hand fairing,
just left of the head lamp, roughly in line with the indicator lamp.

With ignition ON, the pump should cycle for 5 seconds after flicking the kill-switch ON.

Maybe disconnect the pump cable down below, and check for 5 seconds of live each time you flick the kill-switch ON (with ignition ON).

Good Luck.
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Old 08-02-2013, 10:33 AM   #3
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Thanks! I'll give it a go after work today. Do you know if you can force fuel to the carbs by topping the tanks right off, if the pump is not working? I seem to recall folks saying that you can..
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Old 08-02-2013, 11:52 AM   #4
RedRupert
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I don't think it'll work.

Best is to feed the pump with + & - (via a fuse) directly it its connector. If it does not work, then remove it and check the points and make sure the plunger is free.
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Old 08-02-2013, 12:51 PM   #5
RedRupert
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There are two relays side-by-side to the left of the headlight. They are identical, so you can swap them to test.
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Old 08-02-2013, 02:15 PM   #6
Boatman
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950 Adventure will run about 50 miles with topped off tanks before it looses enough head pressure to stop feeding the carbs. A friend of mine had his fuel pump go bad in Canada last yeat and made it home to southern NH stopping for fuel every 50 miles.
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Old 08-02-2013, 04:34 PM   #7
erappaport OP
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I'm getting 12V at the pump momentarily when I toggle the kill switch, but not for anything like 5 seconds. The relay sounds like it's clicking, if I get my ear really close. I'll try swapping with its neighbor, (turn signal?) and see if that makes a difference.

I actually got it to start and run, briefly, but there was no throttle response, and it quit in 20-30 seconds. That tells me there's spark, anyway, so still thinking it's a fuel issue. I'll try pressing up the tanks next and see if gravity pressure does what the fuel pump won't. It's a Facet 40171, BTW, so no points to check...

It's a beautiful day for a ride, too. Damn..
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Old 08-03-2013, 10:34 AM   #8
RedRupert
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If all is well, the Facet pump will pump for 5 seconds every time the ignition + the kill switch are switched ON (not always the case with the OE pump, as that may not pump if good pressure in the pump/carb fuel line). The 5 second cycle is activated by the ECU.
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Old 08-03-2013, 07:38 PM   #9
JRod152
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Petcocks?

Not meant to be a low blow...

I'm sure you have them on, but hey
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Old 08-03-2013, 08:47 PM   #10
dlrides
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3 seconds

Relay runs pump for 3 seconds. If you have switched, constant voltage to relay, but not to pump for 3 seconds, replace relay.
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Old 08-04-2013, 06:04 PM   #11
erappaport OP
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Quote:
Petcocks?
Not meant to be a low blow...
Well, I'll take you at your word and say yes, fuel taps are on.. though I've certainly used up a lot of time in my life chasing other problems with obvious answers.

If the relay is supposed to be providing 3-5 seconds of power on startup, then it ain't. I've got good voltage at the fuse bus, but only a flicker when I turn on the ignition. Time to try swapping relays... I need to figure out what the one next door does before I pull it out to trade.

If I need a new one, I'm sure that KTM is probably to most expensive place to buy.. can anyone suggest a good generic source?

Thanks, ER
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Old 08-06-2013, 12:26 PM   #12
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Well, I pressed up the tanks, and she started first push and ran like a champ! Looks like all fingers now pointing directly at the fuel pump circuit.. time to run through that start to finish, once I can clear out another hour or two.

It would be nice to get at the bottom 90% of my fuel supply, just in case I feel like riding somewhere far away..
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Old 08-06-2013, 01:26 PM   #13
Denalidirt
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Me Too

I also had a problem with my fuel pump this season. Replaced the pump still had the problem. I ended up removing the quick disconnect and soldered the wires. So far so good. check your wires for and weak connections
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Old 08-06-2013, 01:54 PM   #14
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Did you install a fuel filter with the Facet? If so you may want to check it 40171 Facet has a check valve built in. Might want to see if that is a problem. But if it runs with full tanks and gravity feed, must be OK.

Tried jumpering 12 volts directly to pump to take relay and wiring out of circuit?

I don't remember if carbed bikes have a tip over relays like the FI bikes.
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renogeorge screwed with this post 08-06-2013 at 01:59 PM
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Old 08-06-2013, 03:08 PM   #15
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Yeah, now that I know it will run with fuel, I'm going to run through the pump electrics top to bottom.. made up some jumpers today to hot wire the pump, will check relay, all connections, etc. I'll check the fuel filter element too, though I agree that it should be OK if gravity pressure can force fuel through the pump and filter up to the bowls. Funny how gravity always works..

I don't know if the 950 has a tipover relay either. I don't think so, but it would be good to be sure.
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