Fuel pump Clicks non-stop after a few minutes of riding

[Fizzer01]

Hi guys (and girls). I'm new here. So this is my problem..

I have a 1990 FZR 1000, and a few days ago when I started up my bike, the fuel pump clicked about 5 times like it normally does. But after a few minutes of riding, the pump just started clicking away non stop. I was able to get home while this was happening (about 1 km from home). When I stopped, I turned the bike off, and then turned the ignition on again and it was again clicking non-stop for a few seconds. But after I let it sit for an hour or so its back to normal until it starts again after a few minutes of riding. I cleaned out the fuel line from the tank to the pump but made no difference... please help!

Here is a video of what is happening after a few minutes of riding.

[GreyImport]

Welcome!

Is the breather in the fuel cap clear?

Inside of the tank and the internal filters clean?

Fuel filter need replacing?

[Fizzer01]

The fuel filter is good(I could blow though the whole fuel line from tank to pump easily)
I also ran the bike with the tank open to check the breather.
How do I clean the internal filters?
btw thanks for the very quick reply

[GreyImport]

Not sure of the setup on the 1000 .....something like this?

http://www.partzilla.com/parts/detail/a ... 71560.html

You will need to empty the tank and unscrew the petcock....be careful of the rubber "o ring"

Heres how mine looked on the 250 .....
Tank had lots of crud and rust inside also.

[Fizzer01]

Yes the one in the link looks about the same as mine. I found the same crud and rust in my filter so I'll be checking out the tank tomorrow. Thanks.

[GreyImport]

The 250 has a seperate petcock attached to the frame with the actual tap on it.....it comes apart with a couple of screws.
It has rubber seals inside ,so if its possible pull yours apart in case something is part blocking the passageways.

Good luck with it!

[DonTZ125]

Sounds like some of the crap is fouling the pressure switch in the pump. Not sure how to get in there and fix it ...

[Fizzer01]

Maybe I can open up the pump and clean it?

[GreyImport]

If the filter is before the pump (where it should be) then anything large enough to crud up the pump shouldnt get past the filter....but I guess over time particles/gum could build up

If the pump is like the 250 it doesnt look servicable to me.....but thats just my opinion.

Bypass the pump (and unplug it) and have it gravity fed....if thats possible on the 1000 .

Or run the line into a container (instead of the carbys) and see if its flowing properly

[Stig]

Fang over at EXUP1000 did alot of work on the fuel pump and system. Dont have time to search for the posts but its under his username and project bike. The post goes into detail about how the system works and whats involved in testing certain electrical components

[Fizzer01]

So I took off the tank and fuel lines, drained the tank and removed the fuel tap, cleaned everything, and tested the fuel line and pump by letting it pump into a container. I have to say the pump is working 100%, stronger than I imagined. If I plug the outlet with my finger the pump stops and when I let it go it pumps again like it should. No problems. But I found the internal filter of the tap loose inside the tank, along with a small alen bolt (no idea ). I put the filer back in the tap and put everything back together. Went for a ride for about 15 minutes and no problems Still don't know what the problem was or if its completely fixed though... btw, I see there's a extra small fuel filter on my bike thats not standard, but it works so I'll leave it there.

[GreyImport]

Hopefully doing everything has dislodged something that was messing up the flow.

The allen bolt is probably from the fuel cap....I had my cap off and pulled apart the other night and before I put it back I stuffed the hole with a rag so I wouldnt drop any of the bolts inside!

[Fizzer01]

LoL yeah that's probably where it came from