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  #1  
Old 8th April 2011
swtch7 swtch7 is offline
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Default diagnosing a potential fuel/relay problem

Hey Guys/Gals

I was trying to get some help on diagnosing a potential fuel problem on my 2007 EFI sortster 883. Its been sitting in the garage for about 1 year (started every 2 months or so) and no fuel stabilizer has been added.
Here are the symptoms.
-Bike turns over (Charged battery)
-when I would toggle the off/run switch I could hear a “clicking” sound.

I figured the gas gummed everything up so I siphoned it out, nasty smelly gas. I added some seafoam to clear out everything, then siphoned that out and added good gas. Same clicking sound.
I took the gas take off and proceeded to remove the fuel pump assembly out of the tank. When I would switch the off/run button to run I could feel the fuel pump clicking the first time….. tried cleaning it with more sea foam and toggled the switch again, this time to get no clicking or anything.
So, am I looking at a fuel pump issue or a relay problem?

Any help would be appreciated. Thanks!
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Old 8th April 2011
swtch7 swtch7 is offline
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I forgot to mention I did check the fuse's...I have not moved around the two relays yet...

I will pull out the multimeter when I get home this afternoon.
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Old 8th April 2011
jguynn jguynn is offline
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Having had a relay fail with no warning at all, I'd pull both relays then clean the contacts and put them back in. If the problem still exists, swap them and see if anything changes. If you can isolate on of the relays as bad, replace it but be sure to put dielectric grease on all of the relay AND fuse contacts after a good cleaning. The dielectric grease should help keep corrosion down.

One thing is for sure, it's easier to change the relay than it is the fuel pump.
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Old 8th April 2011
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psychodad1961 psychodad1961 is offline
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Besides a click, you should also hear a whirring noise as the pump pressurizes the injectors. Once pressurized, the pump should stop, usually after 1 or 2 seconds.
Sounds like the pump is gummed up and trying to spin but not actually moving.
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Old 8th April 2011
swtch7 swtch7 is offline
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ok i took it a bit further. I removed the fuel pump from the assembly completely and hooked up a 12v source. It would hum but not pump any fluid. I had the pick up submerged in the seafoam in a bucket, didnt do anything.... except hum

bad fuel pump? maybe a rebuild is in order?
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Old 8th April 2011
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Bob F Bob F is offline
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Welcome to the XLForum.
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Old 31st October 2011
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swtch7, what did you find out about your fuel pump, what was the problem?
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