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After long time storage with a liter fuel in tank my bike had following problems like
1) Battery dead
2) Fuel Pump didnt work
3) Fuel injector didnt work
this will sure make a bill around 16k or more so i made up my mind to work on these parts if i can make it work then i save some serious money or else my bad i have to pay for these parts.
The bike didnt start so i checked the battery, its dead. so i used a battery from my activa, it cranked but engine didnt start. then i checked sparkplug its good working fine. when i switched on ignition key i noticed the fuel pump didnt prime.
Battery--- i replaced with Amaron 5 amp battery
Note: Fuel pump removal from plastic mould is not easy try to getting help from a friend preferably do it on sunday or any holiday. get allenkey set (costs around Rs 110) and necessary tools. U need to jump the pump and injector to check it is working so see some articles in web before you start any thing. i have done every thing from help of DIYs articles like how to remove tank, how to jump fuel pump, injector etc. if u not sure about any thing get help from internet or some friend. i am not a certified mechanic or i am not telling this is the way to do it. i am desperate because i dont want to spent like 16k i worked passionately and with patience. Remember you always can give to service center if u dint have time.
Fuel Pump
After removing the tank empty the remaining fuel store it in some bottle. from the image above you can see the bottom of the tank the pump assembly can be removed by removing six allenkey screws.
after removing the screws try to take photos of the assembly its positions before you make any changes, believe me you will need it when re assembling it. In the above image notice the white oval just slide it and remove fuel meter-gauge, remove its wires from the assembly keep it in a safe place . In the orange oval you will find push fit mechanism, there is three of them it will give you a headache in removing it, try screwdrivers as levers to lift the upper part of plastic from bottom one and try to put more force dont be scared it will not break it is very strong piece of plastic. when lifting do not try to remove the black pipe from its position marked in blue arrow and the pipe will allow to bend certain amount in lifting and dont over-bend (because if its damaged then i dont know if you can get that pipe alone as spare) when lifting the top part of plastic.
and after success removing the top part you can remove fuel pump try to connect with battery just for few second it should prime in my case it got hot, so the impeller is not rotating. i took a saftey pin and try to rotate the blades. try not to damage or scratch the blades. in the image below u can see one blade if it was too hard to rotate use some parachute coconut oil and try again it should rotate freely. when it rotates freely try to jump it using battery again. in my case it worked.
then i fitted back fuel pump in assembly and assembled the tank and connections. start the bike if engine starts then its a success. if not check the fuel injector.
Fuel Injector
basically it is a solenoid valve so when it is operating you should hear 'click' 'click' sound.
the arrow in image shows a bolt, can be removed using a ring spanner if u dont have it buy it may cost rs 30. cover the hole in engine using a clean cloth so dust enters the engine.
now connect the injector leads using some wires and touch the wires with battery terminals( use help of friend). touch again and again see if u can hear click sound if u hear it then it is working if not try to hit the injector on floor (gently on plastic side not on metal part) and it started working for me. After 50 times of jumping the injector and some hitting on ground then click sound was clearly audible. When u hold it you feel there is a movement in injector every time the wires touched the battery terminals.
then connect the injector to the bike wiring and this time assemble tank put new fuel from bunk(dont mix the old fuel with new one) about 3ltr or more in tank. Now get the bike to shade and injector away from bike, now start the bike notice the spray of fuel. it should spray fuel. notice the spray pattern atleast it should be symmetrical if it is not then remove injector and clean thoroughly the orifices using alcohol. once the spray is symmetrical then assemble the bike check every connections, and start the bike give it some time it will start.
these things i followed and i made it work, have some patience and it should work for all if the problem raised from storing the bike for long time. the petrol degrades and becomes as a sticky less volatile fuel which made the fuel pump and injector struck. it took 5 days to make it work since i used to see DIYs and articles about fuel pumps and injectors then work on my bike.
These things u may never be sure of are changes in Fuel pump pressure ,flow rate in injector , minor changes in A/F ratio unless you have a awesome garage equipments or test at service center. good luck
.
After Reading the above post then see the below pics for understanding
1) Battery dead
2) Fuel Pump didnt work
3) Fuel injector didnt work
this will sure make a bill around 16k or more so i made up my mind to work on these parts if i can make it work then i save some serious money or else my bad i have to pay for these parts.
The bike didnt start so i checked the battery, its dead. so i used a battery from my activa, it cranked but engine didnt start. then i checked sparkplug its good working fine. when i switched on ignition key i noticed the fuel pump didnt prime.
Battery--- i replaced with Amaron 5 amp battery
Note: Fuel pump removal from plastic mould is not easy try to getting help from a friend preferably do it on sunday or any holiday. get allenkey set (costs around Rs 110) and necessary tools. U need to jump the pump and injector to check it is working so see some articles in web before you start any thing. i have done every thing from help of DIYs articles like how to remove tank, how to jump fuel pump, injector etc. if u not sure about any thing get help from internet or some friend. i am not a certified mechanic or i am not telling this is the way to do it. i am desperate because i dont want to spent like 16k i worked passionately and with patience. Remember you always can give to service center if u dint have time.
Fuel Pump
After removing the tank empty the remaining fuel store it in some bottle. from the image above you can see the bottom of the tank the pump assembly can be removed by removing six allenkey screws.
after removing the screws try to take photos of the assembly its positions before you make any changes, believe me you will need it when re assembling it. In the above image notice the white oval just slide it and remove fuel meter-gauge, remove its wires from the assembly keep it in a safe place . In the orange oval you will find push fit mechanism, there is three of them it will give you a headache in removing it, try screwdrivers as levers to lift the upper part of plastic from bottom one and try to put more force dont be scared it will not break it is very strong piece of plastic. when lifting do not try to remove the black pipe from its position marked in blue arrow and the pipe will allow to bend certain amount in lifting and dont over-bend (because if its damaged then i dont know if you can get that pipe alone as spare) when lifting the top part of plastic.
and after success removing the top part you can remove fuel pump try to connect with battery just for few second it should prime in my case it got hot, so the impeller is not rotating. i took a saftey pin and try to rotate the blades. try not to damage or scratch the blades. in the image below u can see one blade if it was too hard to rotate use some parachute coconut oil and try again it should rotate freely. when it rotates freely try to jump it using battery again. in my case it worked.
then i fitted back fuel pump in assembly and assembled the tank and connections. start the bike if engine starts then its a success. if not check the fuel injector.
Fuel Injector
basically it is a solenoid valve so when it is operating you should hear 'click' 'click' sound.
the arrow in image shows a bolt, can be removed using a ring spanner if u dont have it buy it may cost rs 30. cover the hole in engine using a clean cloth so dust enters the engine.
now connect the injector leads using some wires and touch the wires with battery terminals( use help of friend). touch again and again see if u can hear click sound if u hear it then it is working if not try to hit the injector on floor (gently on plastic side not on metal part) and it started working for me. After 50 times of jumping the injector and some hitting on ground then click sound was clearly audible. When u hold it you feel there is a movement in injector every time the wires touched the battery terminals.
then connect the injector to the bike wiring and this time assemble tank put new fuel from bunk(dont mix the old fuel with new one) about 3ltr or more in tank. Now get the bike to shade and injector away from bike, now start the bike notice the spray of fuel. it should spray fuel. notice the spray pattern atleast it should be symmetrical if it is not then remove injector and clean thoroughly the orifices using alcohol. once the spray is symmetrical then assemble the bike check every connections, and start the bike give it some time it will start.
these things i followed and i made it work, have some patience and it should work for all if the problem raised from storing the bike for long time. the petrol degrades and becomes as a sticky less volatile fuel which made the fuel pump and injector struck. it took 5 days to make it work since i used to see DIYs and articles about fuel pumps and injectors then work on my bike.
These things u may never be sure of are changes in Fuel pump pressure ,flow rate in injector , minor changes in A/F ratio unless you have a awesome garage equipments or test at service center. good luck
.After Reading the above post then see the below pics for understanding
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