FZRSupport: the FZROnline Archive

Ok so I think my fuel pump is out, I turn my bike on and there is no buzzing like normal. If I hit the starter button it wants to turn over but it doesnt seem like it is getting fuel. Now here is the question where is the fuel pump on a 1991 Fzr 600, how do I test it to make sure its not bad and where would be the cheapest place to get a new one? Thanx guys.

The fuel pump in on the bottom of the gas tank. To test it, you can hook it up to the battery directly and see if it pumps.

its on the bottom of the tank...

there is a relay for it that might be fried

come to think of it there was a little string of smoke that came out from under the seat, were is the relay u r talking about?

How would it fry and how do I keep it from frying again?

The one on the left is the relay in question.

If you fried it, then there probably was a short somewhere along the lines. Check the connections and clean if needed.

check the relay and check the fuses...you might have killed the fuel pump fuse as well.

Luckily it's a 2 wire pump. If you've verified the relays and fuses are The FZR 1000 pump will work on the 600 as well so you may want to check ebay for that. A small automotive 5.5 to 9 psi self regulating 2 wire pump will work as well. You just splice into the original harness and you're good.

I hear a clicking noise when I turn the ignition on and off, whats that?

and How do I remove the fuel Pump?

I hold that relay and when I turn the run button on and off there is a for sure clicking what does that mean.

blackeyesandbruises wrote:I hold that relay and when I turn the run button on and off there is a for sure clicking what does that mean.

That usually means the relay is still functional. As far as removing the pump...you have to get the gas tank out and it'll be attached to the bottom. Takes about 5 to 10 minutes to remove the tank.

that clicking noise is your main relay. If it keeps clicking its fried. I fried mine the same way. take that relay and smell it i bet its burnt. I carefully pried mine apart and fixed the burnt traces on the circuit board by soldering a thin wire to reconnect the points. But they are right about the short. You def have a big short somewhere in your wiring harness. If you want pics I can send you one. I also have another relay if you need it. they are 70+ at the stealership

blackeyesandbruises wrote:I hear a clicking noise when I turn the ignition on and off, whats that?

That noise is the relay to your fuel pump putting fuel to the carbs and is PERFECTLY normal and lasts about 3-10 seconds when you first turn the bike ignition on.

Sorry Geo but I must correct you. If you read through his post his fuel pump is not working. That clicking is from his main relay which is fried due to a short. When you fry that main relay on an fzr it keeps clicking non stop. Its a different sounding click that the fuel pump and it never stops

blackeyesandbruises: I replied to your pm and will send you pictures and can walk you through repairing your relay but you need to be looking for a short in your harness or it will just fry again