Ok I have a 02 650 Been running with no problems at all. About a month ago it would not start. Today I decided to tear it down. Replaced spark plugs they were a bit black. But still will not start.

I verified that it is firing and it is indeed. So next i went to fuel problems.



I unplugged the side connection from the fuel valve. Nothing happened.... I tried to blow into it and it is restricted. Also tried to pull gas out no go there either.


My question to the group is Does this think have some sort of a check valve or filter anywhere?

My next guess would be to remove the tank and see what happens. Any suggestions? or ideas?


I have been a lurker for a long time on this forum, but have never posted. I also need to replace my belt soon, if i get the courage.



Thanks guys,


Steve

 

Pulling "side" hose. There's a coupla hoses on the petcock, one comes from the fuel pump (the bottom one faced directly back) and the one that goes to the carb (behind the petcock facing 45º). Easiest way to test is bypass the petcock and hook 'em together.

But, since yer headed for fuel problems and say you have spark which means it cranks.... does the fuel pump pump? Lots of gas should come out of the pump hose if you have it disconnected when you turn the key. If not, check the connections and fuses...

Maybe you have the infamous '02 stuck choke - does the exhaust smell like raw fuel even when just trying to start or when running. Your comment about black plugs leads one to suspect that problem. You can check my page below for a solution...

I also had a problem with my plug caps. When it was wet, it would misfire from time to time. I cut off the Kawa caps and installed NGK plug caps (most dealers about $6 each) and it went away. Way to test for this is wait unitl it's dark, start it up (or at least crank it) and mist a little water on the heads. If you see a light show (like I did) you may need new caps (but not likely in your case, I'm just tossing out ideas).

Experts here will probably have more ideas...

 

Ok No fuel from fuel line as I turn over..... Checked the 4 fuses in the block all are good. Has anyone ever dropped a fuel tank? What is the best way to address the fuel pump?


I have not made any changes to my choke either. I thought about doing it, just did not know if it would be worth while.


Steve

 

Ok I have power on the bottom 2 spades within the plug into the fuel pump. 12 volts on one and 10 volts on the other. All indication to me would be the pump is getting power to it, but is not operating.




Anyone been here before?


Thanks,

Steve

 

Now then Sticker shock!!!!!!!


The fuel pump is 561.00 is the cheapest i found. Anyone know of any aftermarket of a cheaper route?

 

ok i broke down and removed it all. I have broke down the pump to just the pump itself. I belive it's made by mitisubish (sp?) as its stamped on the outer assembly.

The pump runs, it sprays gas from a small home in the top rather than from the discharge.


No I refuse to pay the out rageous price for a pump. Anyone know what kind of flow and pressure the 650 requires so i may fabricate another?

600 dollars is outrageous. The microfich shows the whole assembly only. I very very easily removed the pump, I mean my 6 year old could seperate the pump from the sensor and all.

Ok guys. Need help here. I'm gonna post on some other sites and see what I come up with there.


steve

 

With the pump plugged in, turning on the key and run switch on should cause the pump to work for about 5 seconds and then shut off. When the engine starts, it turns on again. The Igniter, black thing under the seat with 2 connectors on it, controls the fuel pump. It turns the pump on by grounding the wire, so the pump is connected to the battery voltage on one side, and then gets grounded by the igniter on the other side. The igniter also will not turn the pump on if the tip over sensor is faulty or stuck. Good luck.

 

Yes I was having problems trouble shooting that. So i removed the tank and pump. Bypassed all wiring and connected straight to the battery. The pump runs, and it sprays out of the pump itself. No gas comes from the tube it should be coming from. Im leaning toward a diaphram gone bad internally within the pump itself.

Thanks for the help. I really want to get running again, but refuse to pay kawai 600 bucks for a pump.

 

Doesn't help much but they are 396.85 at ronayers.com

Good luck

 

Well I found out is in fact a mitsubishi fuel pump. I broke into it today and removed the top section. I found out this piece is only a check valve. I did manage to get it unstuck. However to prevent having to tear this down again anytime soon I am gonna simply remove the check valve and and place one externally on the tank. This should serve the same purpose. I just cant stand to drop that much cash for a stuck check valve. I mean thats pretty much highway robbery. I know they charge that because they can.




Anyway just got in Gonna try that out and see how it works.



If you guys have any feed back let me know.



Thanks,

Steve