My brother owns a 650 Kawasaki, with 5400 miles on it. The fuel pump has gone out on his 650 for the forth time. He does have the extended warranty and they just keep putting new fuel pumps on it. Does anyone have a clue as to why the fuel pump keeps going out on this quad? He feels that his 650 is a lemon and wishes Kawasaki would buy it back off of him. I can understand his aggravation, because his quad is not dependable.

 

I think he needs to find a mechanic as the problem probably is something either voltage being to low possibly or dirt getting into the pumps also if you use fuel additives some of them are not compatible with fuel pumps - the secret they do not tell you..
To say a quad is not dependable looks like he has gotten 5400 miles out of it and has not yet had to spend a dime on it so how can it be not dependable. I think the quad has a problem that should be looked at because if the same dealer keeps putting pumps on it and they are not clearing the tank of something that is possibly getting by the pumps sock then he will never get it fixed. I love my quad and if the fuel pump goes out it will be just like having an auto that the fuel pump has failed on I will look for the problem and then correct it before replacing the pump. Does the thing have a short that may be showing it head on very intermittently - Check it out.

 

I also have a 650 Kaw, so I am some what familiar with it. I find my quad very, very dependable. The only reason I say that my brothers, Joe's isn't is the darned fuel pump keeps going out all the time. Joe has Multipal System Atrophy that makes having his quad break down on him even more difficult. Think of it this way. You are in the middle of a beautiful ride and you break down. Whether it cost you any money or not you are still broke down, and that is a big bummer, or you could say thats its not dependable.

From what Joe and his technician have sold me is that the tank is clean, and the old pump will not run when power is applied to it. So they just keep putting pumps on it.

Joe has experienced robbing fuel out of the 650 to use somewhere else. When he does this he tells me that he disconnects the fuel line at the shut off valve. When he turns the key on the pump will only run for two or three seconds and shut off. He repetes the process till he has all the fuel he wanted to drain out of it. Learning this we know that pump has an automatic shut of of some kind, some where but where. He does not make a habit out of this. He tells me he has done it twice.

As for the high or low voltage, I would think that the technician that has installed the fuel pumps would have checked that, but I don't know that.

He has not added any fuel additives. I have noticed he does run Ethanol gas in it.

 

Have any of you other 650 owners had any fuel pump problems?

 

Well took it to the shop yesterday and the fuel pump would not run when power was applied. So it's another new fuel pump. They checked everything they could think of to try and figure out the problem and couldn't find anything wrong other than a bad fuel pump.

 

Two words for ya "Call Kawi!"

Those repeated fuel pump replacements are, in a way, on their dime. If the tech can't seem to do anything but keep replacing a fuel pump that continually goes bad then something is wrong somewhere on that machine and he just doesn't know how to find it. Think about it, almost no one has fuel pump problems but this one machine has been through five fuel pumps, you don't really believe that all 5 were faulty do you?

 

Well replacing the fuel pumps fix it. So, yes, I do believe that the pumps were faulty. I would just like to know what is causing the fuel pumps to go out.

 

Wrong answer Sandbags! Those pumps weren't faulty and no, they didn't fix the problem. Otherwise after the 1st, or 2nd time the problem would have gone away. You'll eventually find there has been a voltage spike caused by a fouled relay, faulty stator, or some other such common electrical problem. I suggest you find a qualified tech to deal with this problem as the guy you're presently dealing with is evidently not qualified in electrical. You have to check for shorts, undue amperage drag, etc.

 

I agree Dangerous. If you read my last sentence you can see that I am wondering what is causing the pumps to go out. I don't think the pump is the problem. The problem is what is causing it to go out! They test the old pump to power, won't run. They test the new pump to power, it runs. I agree that when the new pumps are installed they are fine and when replaced they are faulty. Yes I agree the quad needs to be looked at by someone that can find the problem. We have had three different QUALIFIED KAWASAKI TECHNICIANS look at it and they can't find the problem, just throw on a new pump and we will see you in a month or so. At this point I feel that if it goes out again Kawasaki should replace the quad.

 

I had trouble starting my 650. Sometimes it would be ok, other times dead. Long story told short.................The red kill switch on the left handlebar got some corrosion on it. So it was making a bad electrical connection. I'm pretty certain this switch controls the fuel pump, because when off the fuel pump doesn't run. When turned on you can hear the fuel pump. I just took it apart and cleaned it real good - all fixed. Maybe his switch needs cleaning and is causing voltage spikes to the pump? Just an idea.