Hi guys,
Well I bought my 99 Busa a couple of months ago now, and being only on my RE licence, I haven't gone further than about a Km from home. Yes - frustrating! Anyway in saying that, she also has never been riden for longer than about 5-10mins. One trip, I ran out of fuel (well so I thought). Topped her up, made sure it started and put her away again. Next time, I ran for about 5 mins then it conked out in 2nd gear. Started her up again, got about another 400m and stopped again. Started her up and got 200m to my driveway and she stalled again. I since have not been able to start it again. I also noticed (that last time) that the fan kept coming on too because she was hot for some reason from the short trip (if this helps).
I have replaced the fuel tank filter, all the injection seals, overhauled the injection pump with new seals, strainers and filter and replaced fuel lines. I also replaced my vacuum hoses.
I have applied power to the pump and verified that fuel flows when I turn the iginition on  . I also can run the bike kinda happily buy spraying aerostart into the airbox (so I think there's no issue with spark or mechanical).
I'm about to take it to Suzuki unless someone else has any bright ideas for me.
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26-08-2010, 07:39pm
(This post was last modified: 26-08-2010, 07:41pm by simmo.)
When you drop the tank back down check the fuel hose isn't kinked
or I guess you have tryed running it with the tank up
Sound like the pump
When you turn the key on can you here the pump fire up
Have you changed the fuel filter & checked all the little screens in the pump also
(26-08-2010, 07:39pm)simmo Wrote: When you drop the tank back down check the fuel hose isn't kinked
or I guess you have tryed running it with the tank up
Sound like the pump
When you turn the key on can you here the pump fire up
Have you changed the fuel filter & checked all the little screens in the pump also
Tried starting with tank up & down (although it shouldn't be kinked as it just happened seemingly out of the blue on that 5min run). But in saying this, the bike has never been ridin longer than about 5-10mins since I bought it (so I hope a previous issue hasn't popped up). Yes, I replaced the filters and screens too. No luck, but thanks anyway.
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26-08-2010, 07:50pm
(This post was last modified: 26-08-2010, 07:56pm by fasterfaster.)
Faulty fuel pressure regulator (block the fuel return line and see if it makes a diff) Pump must have correct pressure AND flow rate. Fuel coming out will not suffice as a pump check it can flow all day at 20psi and the bike will not run. May also pay to re strip pump and make sure no pinched "o" rings on re assembly. I'd go with the Lesbian hunter but and say the pump is the culprit.
(26-08-2010, 07:50pm)fasterfaster Wrote: Faulty fuel pressure regulator (block the fuel return line and see if it makes a diff) Pump must have correct pressure AND flow rate. Fuel coming out will not suffice as a pump check it can flow all day at 20psi and the bike will not run.
Thanks for that. I'll give it a go tomorrow and let ya's know how I went. Just to confirm, I can pinch the return line back to the tank and it should start (assuming the regulator is at fault)?
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Thats it ............. if regs not holding pressure it will just let fuel circulate via return. I think you will find it's lack of fuel pressure but as in a faulty pump.
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26-08-2010, 09:06pm
(This post was last modified: 26-08-2010, 09:12pm by Greeny_SA.)
Did you replace the small white plastic screen fuel strainer which fits in a hole in the body housing ?It's smaller diameter than a 1 cent piece & Easy to miss.I had problems with my 2000 which also has the external pump,& it turned out to be this $7-50 filter. It can be replaced with the pump in place by just lifting the tank. The best pic i can show you is on the alphasports.com site go to 2000 Hayabusa Diagram No35 Part No 26 . If you have not replaced this as yet you will have to eventually, so
its worth getting a couple About $7-50 .I'm not saying this is your problem but it's worth checking ,Only us 99-2000 owners ever have to think about it,but you have to live with that if you own the fastest models to come off the line .The speedo says it All..
If Wisdom Comes with Age , I'm one of the Smartest Blokes Here
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26-08-2010, 09:31pm
(This post was last modified: 26-08-2010, 09:32pm by BSA.)
I had similar symptoms and I intend to replace the fuel pump relay.
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26-08-2010, 10:39pm
(This post was last modified: 26-08-2010, 10:42pm by CarbonBusa.)
(26-08-2010, 09:06pm)Greeny_SA Wrote: Did you replace the small white plastic screen fuel strainer which fits in a hole in the body housing ?It's smaller diameter than a 1 cent piece & Easy to miss.I had problems with my 2000 which also has the external pump,& it turned out to be this $7-50 filter. It can be replaced with the pump in place by just lifting the tank. The best pic i can show you is on the alphasports.com site go to 2000 Hayabusa Diagram No35 Part No 26 . If you have not replaced this as yet you will have to eventually, so
its worth getting a couple About $7-50 .I'm not saying this is your problem but it's worth checking ,Only us 99-2000 owners ever have to think about it,but you have to live with that if you own the fastest models to come off the line .The speedo says it All..
+ 1, If it was running rich then that would be the first thing I would check & make sure the return feed hose runs BEHIND the breather pipe running to the airbox & watch that the return fuel line does not kink as you drop the tank.
If it did not seem to be running rich then look at the Pump but I would still do the strainer in the pressure regulator first as a maintenance thingy because it is a bad flaw in the design & why they put the Pump in the tank on later models.
I would also treat it to some new GENUINE fuel lines if never been done 
Also be prepared to catch petrol when you pop the lines.
Heaps of rags on motor & a cut down ice cream container are my tools of choice. There are a couple of Rubber Plugs under the hump that act as Fuel block offs. (Hopefully they are still there)
My 99er would cut out all the time & be a bitch to fire back up, I replaced the strainer which was totally clogged & never had a prob since 
Isn't it Ironic that my Favourite Stretch of Tarmac is called C.O.P. 
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I had a bike to fix do a similar thing. The filter was full of shit. So once the fUel i'n the line ran out the bike stopped until enough fuel seeped thru for another 2min fun. My cousin gave it to me thinking it was a lost cause and I fixed it for $4.
Probably completely unrelated as this was not fuel injected!
Well, thanks guys. I think "FasterFaster" was on the money. I blocked off the return fuel line and she started like a dream! So assuming my vacuum is correct, this tells me that the pressure regulator is stuck open and requires replacing, yes?
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(26-08-2010, 07:50pm)fasterfaster Wrote: Faulty fuel pressure regulator (block the fuel return line and see if it makes a diff) Pump must have correct pressure AND flow rate. Fuel coming out will not suffice as a pump check it can flow all day at 20psi and the bike will not run. May also pay to re strip pump and make sure no pinched "o" rings on re assembly. I'd go with the Lesbian hunter but and say the pump is the culprit.
Lesbian hunter, onya
Cant help you with the pressure regulator Pete Woodstock Pittsop could help you there
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Silly question, do the 99's have the sidestand cut out switch? Could this be the issue?
Regards,
John
(03-09-2010, 12:05pm)John Wrote: Silly question, do the 99's have the sidestand cut out switch? Could this be the issue?
Yes they do, but wasn't at fault in this case.
Well, I finally got her going today!
Took it to a mechanical friend of mine where we had equipment to test the fuel pump. When it stalled the injector pulses were still going and the fuel pump still had voltage. So no ECM issues. The fuel pressure was about 40psi but was fluctuating down and up about 7 psi which he thought was odd. Each time (after priming by turning the bike on without starting it) it was just lose pressure and stall after about 30 secs. Looked like the pump at first except for the consistancy of the stalling time and the low mileage for pump. So he scratched his head and insisted that he remembers seeing similar results in cars with fuel supply issue; "it's not that it's loosing pressure, it's running out of fuel each time". This is apparantly typical of overhauled engines, panel work, fuel tanks that have been removed etc, so he suggested I swap the fuel lines around. I did and bingo! Consistant fuel pressure! After all this time, my fuel supply & return lines were ass-about. This is how I bought the bike and explains why I thought I ran out of fuel but actually didn't. It had that symptom because the fuel level couldn't go down the pipe of the return line, and priming it with the gravity fed fuel from the wrong line was just enough to keep it running for a short period until the pump housing drained. Not a problem I noticed when I first got her because it always had plenty of fuel.
So in the end, it was easily fixed but it just goes to show that it can happen - for reasons unknown though.........
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