Hello, John Talley here with Partzilla.com.
Today we're going to be looking at the fuel system on our 2007 Suzuki GSX-R 1000.
Specifically, this one doesn't want to prime up.
You turn it on, you hear the actuators, but you should also hear the actual fuel pump
building up pressure, and that's not happening with this unit.
So, let me go grab a couple of tools, and we'll start digging into this thing and see
what's going on.
Alright guys, this is going to be a skill level one so it's really not going to be that
tough and there's not that many tools required.
You will need to go get a good volometer, a test light, 3/8ths ratchet as always, an
extension, and a 5mm Allen.
Now as far as the parts, if you would reference our parts diagrams.
This gives you an exploded look at where everything is and how it comes apart, and more importantly
how we're going to put it back together.
So once you have your tools and your parts together, we can go over there and I'll show
you how to get it done.
Alright guys, let's start off by looking at our fuel pump relay.
It's this one right here.
And initially, let's lift it up just with your fingers you should be able to feel it
click if it's actuating at all.
Yeah, I can feel it, and then cut it back off.
Because then normally what you would hear is you'd turn it on, it would prime up the
pump for maybe a second or two, and then shut off.
Because it doesn't run continuously, it just brings up the pressure to 43 pounds and just
keeps it there and only cuts on when it starts falling below.
So, I believe this one is actuating, and the color that we're looking for is on the bottom
side.
It is yellow with a red stripe.
That should go active for maybe a second or two and then shut off.
Now let's see what she's doing.
Ground our test light, get on that one wire, and let's see if she's triggering.
Alright, there it is.
And then off.
Alright, so that tells me we're getting power to the relay and the relay is then sending
power up to the fuel pump itself.
So, looks like we're going to have to dig a little bit further.
Let's put our relays back where they were, where they don't get damaged, and then we're
going to lift the tank up and verify that there actually is power going through the
harness up to the connection that leads into the fuel pump itself.
Alright, there's our yellow with a red stripe, and one side of that's going to be a ground
and the third wire, that actually goes to the fuel level sensors inside the tank.
But the only one we really care about right now is the yellow with a red stripe.
So we're going to unplug it and see if we're getting voltage there when we turn on the
key.
Now remember once again that this is only going to be powered on for a couple of seconds
and then it's going to go off.
If it's working correctly.
Yep, there it is.
Now off, plus you can hear the relay clicking, so let's go ahead and get the tank disconnected
and we'll put it over on the teardown bench and get that fuel pump out.
Alright, we've already got the electrical disconnected, and next we're going to take
off the actual fuel line.
Now, of course ours has not been operating correctly.
It does not have any pressure.
So, this is no big deal.
But, if you were taking off your tank and yours had been priming, it's going to have
43 PSI there.
So you need to be careful, otherwise it's going to spray you and everything around you.
Other than that, there's two breather lines all the way at the back, pull those free.
Now we can lower it down and take out that rear pivot bolt and she'll lift right off.
When you lift the tank off, there's actually a spacer that's inside of the tank.
You want to make sure you don't lose that.
Alright, let's flip it upside down and remove the actual pump.
Now fortunately for me, there was only a gallon or two left in the tank.
If yours were full, I would suggest that you open it up and siphon out as much as you can
get out.
Because trying to wrestle around a tank that's full of fuel, that's a little bit too much
for anybody to deal with because you're talking about, I don't know.. 50 or 60 pounds maybe?
More than I want to deal with.
And there she is.
Alright, so we've got it out and the last connection I want to look at is actually right
here, because this wire actually travels right up to the positive side of the motor itself.
So, I'm just going to do a resistance check going from ground to that line.
It should read somewhere just a little over an ohm.
And guess what?
It doesn't read anything.
Now actually I could have-- I probably could have tested this with it still in the fuel
tank, I wanted to get it all the way out because I have seen them where they had a bad connection
right here, but that is not the case.
And there's an open circuit.
so that tells me that My motor is gone.
And here's the trick: with Suzuki you can order every singe individual piece except
the actual pump itself.
so, for me to fix this I'm going to have to replace the entire assembly because that is
the only way you can get the pump.
Alright guys, here it is, straight from Partzilla.
What I wanted to show ya'll was what the reading should look like on a pump that is working
properly.
Brand new, ready to go.
Alright, flip our meter on.
Same thing we did on the other one.
Just going to this ground and then over to this blue wire.
Let's see what we've got.
Yep, a little over an ohm.
Just for fun, keep that on the ground and go to your fuel level.
Watch this.
Alright, it's a 4.2, it'll probably ramp up to around 40 as I move it up.
50... 80.
Yeah, that's running through it's whole range right there.
But we weren't concerned with that because the fuel level actually worked.
But this is what one would look like if it were in working condition.
As I said before, we can't replace just the motor, we have to replace the entire assembly.
So, let's get it popped back in, just going to be a reverse of what we did.
Let me go grab the fuel tank, get it put in place, and we'll get it put back on the machine.
Don't forget to put this back in.
Now let's tilt her back and let's get our vent lines back at the back.
Make our fuel line connection.
It just pushes on, make sure those plastic tabs are lined up where they go inside the
collar.
And then make our electrical connection.
Now, let's see if we hear her prime up now.
That's what we were looking for, right there.
Let's cut it off, prime it up one more time.
Alright, let's see if she starts.
Well, she starts up but I can tell you right now it's still got a few other issues.
Well that's as far as we're going to take it on this particular video.
Well listen, if you need any of the parts that we used to get it this far, why don't
you come see us at Partzilla.com and we can get you taken care of.
If you have any questions or comments just leave them in the section below and I'll do
my best to answer them.
Until next time we just want to say thanks for watching.