How to: Check fuel flow

[mjc506]

This incredibly long and technical post should hopefully show you how to test your fuel pump for adequate flow you may wish to do this if your bike bogs under WOT conditions, fails to start (ie, is there any fuel flow at all?), or if you just need to empty the tank and don't want to syphon it out

I'm assuming that you've removed the plastics and lifted the tank. You will also need a 12v power supply (ie, your battery) and two leads long enough to reach from it to the fuel pump connection. A stop watch or wall clock with second hand is kind of useful, as is a measuring jug/old clear (clean) container - a jam jar works OK here. You will also need a flexible hose to connect to your fuel tank. I used the fuel delivery tube (I unclipped it from the throttle bodies) but it may not be accessible on an assembled bike. You could use the overflow/water/crap tube that runs from the RHS of the tank and drains by the RHS footpeg - pull it out of the bike in this case.

The following pictures show the tank completely off the bike, and mine is in a state of... disassembly. This procedure is easier while the tank is on the bike. Also make sure you have at least one 'blob' of fuel!

Step 1) Remove plastics, and lift the tank. Detach the fuel delivery hose and fuel pump connection. Mop up any fuel that drips out.

Step 2) Measure out 168ml and mark it on your collection jug/jam jar. The fuel pump should pump this much liquid in 10 seconds.


Step 3) Make sure the collection jug is completely dry and clean (assuming you want to reuse the fuel)

Step 4) Set up! Connect your hose to the fuel tank discharge port, and hang the other end in your jug. Connect your leads (crocodile clips are easiest) to the fuel pump connector - -ve to black/white, and +ve to yellow/red. Connect the other end of the negative lead to the black terminal on your battery.

Please bear in mind that you're playing with fuel and electricity - don't short anything out, or you get a nice combination of fuel and heat...

Step 5) Make sure you can see your clock/stopwatch. Hold the +ve lead to the +ve battery terminal, and hold it there for 10 seconds (don't worry too much about split second accuracy - if you're borderline enough for it to make a difference, you probably have problems)

Step 6) Be happy - the fuel pump has pumped more than the minimum required


Step 6 (alt) Be sad - the fuel pump hasn't pumped more than the minimum required You'll need to perform the external fuel filter mod at best.

Step 7) Clean up, and reassemble the bike

oh, ermmm

 

[Walruzoar]

Hi fellas

OK, fuel flow rate test run. Good news & bad news...
1) 168ml in 10secs - approx OK.
2) The "petrol" that ended up in the jam jars was disgusting! Yellow, cloudy & rust particles...
http://www.flickr.com/photos/donline/sets/72157634927905602/

I think the filter will need changing - it's going to look nasty coz this "fuel" is from the "clean" side!!!
Anyone have any ideas about cleaning / de-rusting the inside of petrol tanks?
 

[Walruzoar]

The rust is bad isn't it?
Honestly, you should have seen the fuel as it was being pumped out, cloudy & yellow, with rust particles!
That's what happens when you lay a bike up long term with no prep...

Spent ages looking up various articles, and have come to a cheap & safe option.
Some of the options sounded a bit dangerous & quite pricey.
I think this should work & has less likelihood of killing me & Suzi!

1) Remove tank, filler cap, pump/filter assy.
2) White vinegar & ball bearings. Wash, rinse, repeat - until comes out clean.
3) Nutralise acid with baking powder solution.
4) Dry tank thoroughly.
5) Wash tank out with fresh fuel.
6) WD40 blasted all round the inside.
7) Reassemble tank with new internal filter (also possibly ext filter) & bottom O ring, etc.
8) Keep the tank fairly full to avoid condensation & ride regularly (no great hardship there!).
9) Do not leave the bike in storage for 2 years (how I bought Suzi).

Some good articles:

http://uk.answers.yahoo.com/question/index?qid=20110910082108AAvU28R
http://www.mopedarmy.com/wiki/Removing_rust_from_a_gas_tank

I like the sound of http://www.tankcareproducts.co.uk/ & might go for this once I cleaned out all the nasties from the tank.

Fingers crossed! :eusa-pray:

[mjc506]

holy sh*t!

Good luck with the cleanup. I would still consider Crazyhorse's offer and get it painted, as the amount of rust in there must be staggering!

[Walruzoar]

Right! Looking better - the situation has improved drastically!

I have restripped the bike. Throttle bodies & butterfly valves - squeaky clean.

Pumped & filtered all the fuel from the tank.
Coating the inside of the tank / at the bottom - was a nasty sludgy mess.
Washed out with some petrol: almost rust free!

Removed fuel pump assy from tank - what a mess - massively gunged up.
Stripped the pump assy - horrendous! Thick brown sludge, often dry & solid.
Washed the gunge & deposits out! Cleaned out fully, temporarily rebuilt.

https://plus.google.com/photos/109105353880364617519/albums/5909429782350987777

I have got one of these on order with Haslemere M/Cs:
1542005H00 Strainer Fuel Pump Suzuki DL-650 V-Strom '07-'11.
Hopefully with me on Friday.

I may have Suzi back on the road for the weekend!  

[mjc506]

Holy crud!

[Jacko]

I'm going to stick my neck out here and say the bike will be running slightly better once it's all put back together clean. I know, bold prediction, but I'm quietly confident. ;)

[mjc506]

I imagine you might be right

[Walruzoar]

I'm certainly hoping that you're right!
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