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Discussion Starter #1
Hi everyone, I'm James. Sorry this is my first post but I need some help with my 954.

I've got a 954 FireBlade that I took the tank off to get sprayed, whilst it was away I fitted a PCIII and the quick release fuel couplings.

I got the tank back rigged it all up and initially the pump wouldn't prime when I turned the ignition on. The next time I tried it the pump primed but it doesn't start. I've ruled out the fuel cut off relay as I swapped it for the headlight relay, I've disconnected the PCIII.

Still no joy, then I put new fuel hoses on without the quick release couplings, the fuel pump connector is getting 11.8 volts so that's not the problem. It's sparking as I sprayed carb cleaner in the throttle bodies and it fires straight up so it's definitely fuel related.

I then ran the pump constantly off another battery and tried to fire the bike up but still nothing. It's not showing any FI codes on the dash, anyone got any other ideas?

I suspect it is the pump but don't have another to test it against. If it is the pump how on earth did it just give up the ghost?

Another odd thing is I don't think the fuel level sensor is working as there is only a few litres of fuel in there and it isn't on, it also doesn't light up when you turn the ignition on.
 

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Hi everyone, I'm James. Sorry this is my first post but I need some help with my 954.

I've got a 954 FireBlade that I took the tank off to get sprayed, whilst it was away I fitted a PCIII and the quick release fuel couplings.

I got the tank back rigged it all up and initially the pump wouldn't prime when I turned the ignition on. The next time I tried it the pump primed but it doesn't start. I've ruled out the fuel cut off relay as I swapped it for the headlight relay, I've disconnected the PCIII.

Still no joy, then I put new fuel hoses on without the quick release couplings, the fuel pump connector is getting 11.8 volts so that's not the problem. It's sparking as I sprayed carb cleaner in the throttle bodies and it fires straight up so it's definitely fuel related.

I then ran the pump constantly off another battery and tried to fire the bike up but still nothing. It's not showing any FI codes on the dash, anyone got any other ideas?

I suspect it is the pump but don't have another to test it against. If it is the pump how on earth did it just give up the ghost?

Another odd thing is I don't think the fuel level sensor is working as there is only a few litres of fuel in there and it isn't on, it also doesn't light up when you turn the ignition on.

Is the bank angle sensor correctly mounted?
 

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I'd be suspicious of your fuel pump regulator. But I'd also test the fuel pump for the correct fuel flow. And test pressure too, if you can get a gauge to test that. Or just replace the fpr and hope that fixes it.

Just to clarify, you are getting the proper prime when you turn on the ignition switch? Because you bank angle relay is tied into your fuel pump relay. Check that BA relay and check the BA mounting is proper too.
Also check your sidestand switch, that can cause a no start.

And lastly, do you have a good strong battery? It needs to read at least 12.5 VDC or more at rest. Use a jumper battery if any doubt.
 

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Can't believe this has been overlooked... Disconnect your PCIII and reconnect the two stock harnesses to rule out a faulty PCIII. After that, I would start double checking any electrical connections to make sure they are all in and tight. If it was running just dandy before the changes, it usually means you mucked something up accidentally while re-installing everything. I know it sucks to think you are the problem, but I know from experience (many times over) that things can get overlooked when you are happily re-assembling...
 

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Discussion Starter #5
I haven't touched the bank sensor, does that kill the spark or the fuel injection because it sparks fine and dandy. I have unplugged the pc3, yeah it was running fine which is why it's so annoying. I hardly unplugged anything. Some one else removed the fuel pump from the tank but he says it wasn't damaged in any way. Could the fuel pump be faulty but still pump but not generate enough pressure? It doesn't attempt to start or fire at all like complete fuel starvation.

I'll check the fuel pressure regulator tomorrow, can you repair them with a new diaphram or is a new one from Honda the only option? Could the fpr stop it from running completely?
 

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Discussion Starter #7
Which hose is the return to the fuel pump? Does the pump pressurise the right hand side of the fuel rail or the left? If it's the right then I know what's the problem....:rotfl:
 

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I haven't touched the bank sensor, does that kill the spark or the fuel injection because it sparks fine and dandy. I have unplugged the pc3, yeah it was running fine which is why it's so annoying. I hardly unplugged anything. Some one else removed the fuel pump from the tank but he says it wasn't damaged in any way. Could the fuel pump be faulty but still pump but not generate enough pressure? It doesn't attempt to start or fire at all like complete fuel starvation.

I'll check the fuel pressure regulator tomorrow, can you repair them with a new diaphram or is a new one from Honda the only option? Could the fpr stop it from running completely?

Have you tried starter fluid?
 

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Discussion Starter #9
Yeah I sprayed carb cleaner into the airbox and it fired straight up. Which hose goes to which end of the fuel rail as I may have the mixed up?
 

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Yeah I sprayed carb cleaner into the airbox and it fired straight up. Which hose goes to which end of the fuel rail as I may have the mixed up?

It's not possible to mix them up, only the right end of the fuel rail is threaded to take the banjo from the tank. The low-pressure return hose comes off the regulator at the left end of the rail.
THROTTLE BODY ASSY 02-03

FUEL PUMP 2
 

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Discussion Starter #11
Maybe just maybe I err I mean my mate chopped the lines to fit quick release couplings and when putting it back together put the fuel lines the wrong way round. Haha what a knob I am err I mean my mate is! Started first stab of the button once corrected! :)
 

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Maybe just maybe I err I mean my mate chopped the lines to fit quick release couplings and when putting it back together put the fuel lines the wrong way round. Haha what a knob I am err I mean my mate is! Started first stab of the button once corrected! :)

I hope the fittings and the crimps to the hoses are rated to hold more than 50psi.
How often do you expect to be removing the fuel tank?
 
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