[SafetyHazard]

So, I picked up a 95 ZX7. I drove it home, and when I went out to ride again, it wouldn't start up. It would crank, and crank, and kind of start up, but then die out. If I spray gas directly into the carbs, it'll start up fine, but die out once the fuel is burnt up. Then I noticed the fuel pump wasn't pressurizing. It would try, but get nothing. So I got a new fuel pump and when I was taking apart the bike, and getting ready to replace the pump... I noticed the wires for the pump were wired to a fuse, and grounded on the bike.... Not plugged into it's normal spot. So, I hooked up the new pump, and now it's not getting power... What would cause this?

 

[Masta Squidge]

A bad fuel pump relay. Assuming you have it properly connected to the harness the way it is supposed to be.

Sounds like PO had a shitty bypass going.

That is why you should diagnose before buying parts. Those pumps are expensive lol

 

[SafetyHazard]

They really are very expensive. Where is the pump relay at?

 

[Masta Squidge]

Its the black/red relay under the seat on a P model. On yours I don't know.

 

[SafetyHazard]

Any chance this is it?

[/IMG]

 

[SafetyHazard]

Sorry about the giant image.

 

[ninjanut]

That would be the fuel pump relay.
:mfclap

 

[SafetyHazard]

-.- ... Your emoticon made me feel stupid. Lol. Well, now I just need to replace this, and hopefully everything will be fine.

 

[ninjanut]

Sorry, nothing meant by it. Just keeping things light-hearted. Have you checked the relay and the wiring yet???

 

[Masta Squidge]

Yeah lol that is it.

Verify that it is the problem before you go replacing it.

 

[SafetyHazard]

How do you test the relay?

 

[Masta Squidge]

A service manual will tell you specifically, I strongly suggest getting one if you do your own work on the bike.

But the idea is that you find out which pins do what, then make sure the relay is... relaying.

 

[SafetyHazard]

Anyone have a PDF copy of the manual?

 

[SafetyHazard]

Okay, i got a new relay, but the fuel pump still won't kick on! Do I need gas in it for it to kick on, also, my batter is too dead too start, but gauge cluster gets power. Do I just need more juice?

 

[Masta Squidge]

Always work with a charged battery on these bikes. If the voltage is too low most of the relays on that bike cease to work.

 

[SafetyHazard]

Got the bike fully charged, got some gas in the tank, tried starting it, and nothing. The fuel pump is STILL not getting power. I've checked all the fuses, replaced the relay, checked the wires, and I am at a loss....

 

[Masta Squidge]

The pump doesnt have to run to start the bike you know.

If the carbs are full, and you have a full tank, it will gravity feed just fine. The pump also will not run unless the motor is running/cranking.

If the bike won't start, and your carbs are full, then you have other problems. If the carbs are full, the pump won't run either. Its not like a fuel injection setup where it has to build line pressure.

 

[SafetyHazard]

Wait, really? I don't even think there is any fuel in the carbs.

 

[NoSaint]

Find the positive wire that goes directly to the fuel pump from the relay. Put positive power directly to it from a battery temporarily. So long as the pump is grounded it should pump when power is put directly to it. If the bowls are empty the pump will click rapidly for a few seconds. If the bowls are full it may click once or not at all. If it clicks then it is a sign the pump is likely ok. If it hasn't clicked yet by just applying power then try starting the bike and it should start clicking and pumping. If you can't hear the clicking and you can touch the pump then you will feel the vibration from each click. Pump is likely OK, but it only means the contacts are working and doesn't mean for sure it is pressurising. If the clicking starts and then stops it is likely pressurising OK. When the bike is idling the pump will click every second or so.
If the pump is OK then you have a power delivery problem from the relay or power isn't getting to the relay. Check the grounds to the pump and relay.