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Thread: Fuel pump stripped, cleaned and working, but no feed.

  1. #1
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    Fuel pump stripped, cleaned and working, but no feed.

    Does anyone have any idea why I'm not getting juice from the main loom to my fuel pump? I've stripped, cleaned and checked, bypassed the electrics and it spins up just fine. I noticed there was a serious kink in the braided hose that ends in a banjo and disappears under the air box, could this have caused the pump to overload and blow a fuse or is there a relay somewhere?

  2. #2
    apriliaforum expert RAS's Avatar
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    Quote Originally Posted by Zanx View Post
    Does anyone have any idea why I'm not getting juice from the main loom to my fuel pump? I've stripped, cleaned and checked, bypassed the electrics and it spins up just fine. I noticed there was a serious kink in the braided hose that ends in a banjo and disappears under the air box, could this have caused the pump to overload and blow a fuse or is there a relay somewhere?
    The kink in that expensive hose comes from someone attaching it to the tank with it upside down. Flip the tank upright and that puts a half twist in the hose. when the tank is put back down into position, the back pulls it tighter and this causes the kink.

    You probably should replace the hose as that sees fuel under pressure. The kink can cause the interior lining to crack allowing fuel under pressure to leak.

    Sure check fuses. The "B" fuse in front is for the fuel pump.

    The #8 relay is for the fuel pump. #9 is the "engine stop" relay and it also must be OK. A faulty tip-over sensor will also shut off fuel at the pump. That sensor is up inside the fairing, behind the dash
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  3. #3
    apriliaforum expert RAS's Avatar
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    This will also help. Start at the fuses, then work backwards from the fuel pump relay to the engine stop relay and then the tip over sensor. It'll likely be one of the relays if not a fused they are easy and cheap to replace. The tip-over sensor is something you'll have to bypass if it's failed. They don't exist new
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  4. #4
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    Quote Originally Posted by RAS View Post
    The kink in that expensive hose comes from someone attaching it to the tank with it upside down.
    Having recently disconnected and reconnected that hose, I can testify that it's a head-scratcher to reconnect, and upside-down doesn't seem that much different from rightside-up when you have the tank up in the air and are trying to figure out what to do. (I hope I managed to do it right, actually!)

    It's weird that Aprilia didn't put a quick-disconnect on both lines, but maybe those are expensive. And space is definitely limited in that area. Or, since I think they were using plastic QDs at the time, maybe the plastic disconnects couldn't stand up to the pressurized side of the hose?

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    apriliaforum expert RAS's Avatar
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    Quote Originally Posted by spacewrench View Post
    Having recently disconnected and reconnected that hose, I can testify that it's a head-scratcher to reconnect, and upside-down doesn't seem that much different from rightside-up when you have the tank up in the air and are trying to figure out what to do. (I hope I managed to do it right, actually!)

    It's weird that Aprilia didn't put a quick-disconnect on both lines, but maybe those are expensive. And space is definitely limited in that area. Or, since I think they were using plastic QDs at the time, maybe the plastic disconnects couldn't stand up to the pressurized side of the hose?
    It's a bit of a pita to get that banjo bolt started with the tank up at an angle and not much room to get a hand in there. Especially if you have big hands.

    The 1st and last time a dealer worked on mine was to replace the pump plate o-ring under warranty. Next time I was under the tank, I found that fuel line kinked like a cheap garden hose. Cheap it's not - I ate that mistake of his as he wasn't gonna even consider it.

    with it twisted 180 like that, it'll look just fine with the tank up, but the way the tank pivots, what little play were is in the hose gets pulled sorta straight and where it bends round the TB, it kinks flat. Oooo, it makes me so angry, lol.

    Consider the number of Futuras that have caught fire due to fuel leaks from the non-pressure side, eh, I'm perfectly happy with solid connections on the pressure hose.

  6. #6
    apriliaforum expert spaz_666's Avatar
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    Quote Originally Posted by spacewrench View Post
    It's weird that Aprilia didn't put a quick-disconnect on both lines
    I added a QD to my high pressure line between the pump plate and the throttle body.

    I got a 1/4 inch Goodridge in-line fuel quick disconnect coupler with Viton o-rings and had the fittings professionally machine crimped by a local hydraulic hose specialist. Looks OEM, just like the updated Caponord line.

    This mod has made completely removing the tank a breeze, and eliminates the potential of kinking the line since the coupler adds a point of rotation.

  7. #7
    apriliaforum expert RAS's Avatar
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    I had some plastics off yesterday to nose about and it would seem that based on the wire colors - at least on my bike - the service manual got the engine stop relay and fuel pump relay swapped.

    I've never touched these, so it's been like this since new. That would make #8 the engine stop relay and #9 the fuel pump. The circuit diagrams sorta shows it like this left to right with the tip-over sensor between them.

  8. #8
    apriliaforum expert RAS's Avatar
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    Quote Originally Posted by spaz_666 View Post
    I added a QD to my high pressure line between the pump plate and the throttle body.

    I got a 1/4 inch Goodridge in-line fuel quick disconnect coupler with Viton o-rings and had the fittings professionally machine crimped by a local hydraulic hose specialist. Looks OEM, just like the updated Caponord line.


    This mod has made completely removing the tank a breeze, and eliminates the potential of kinking the line since the coupler adds a point of rotation.

    I seem to remember you doing this. Nice.

    I hope to never have to pull my tank off - ever again.

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