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Beugs
Posted on Monday, August 08, 2016 - 08:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I've got a 2009 1125R, 20,000 miles or so. I was riding one day in march and it suddenly cut out and I parked it on the side of the road. I went and got it later with a trailer and got it home, and put it on the tender right away like I do every night.

I started by pulling off the fuse box cover and found the fuel pump fuse blown. I grabbed another fuse, put it in, turned on the ignition and it blew again. At this point I started checking for shorts and all that fun stuff using the electrical diagnostic manual. I found no issues anywhere, everything tested perfectly. I put it all back together, put in another fuse, and it fired up and ran. While running I wiggled every wire loom and connector I could get my hands on, nothing happened, it just kept running. I then checked the codes and had three codes, two for fuel system/pressure errors, followed by fuel pump fault. While running, fuel pressure swung between 2?? and 5??, couldn't get an accurate read because it changes very quickly.

My big question is, can low voltage issues cause a fuel pump fuse to blow? Keep in mind I had it on the tender this whole time so voltage was increasing. Since I couldn't find a problem I replaced the battery and start it every once and a while and it runs just fine. Problem is I haven't left my garage with it because I don't have the time to be calling friends and family to come bring me home to the Jeep if it dies. I want to know if I can trust this thing or not.

I have done a ton of searching on here and elsewhere (notice the problem first happened in March?) and haven't found anything that is definitive for my issue. Unless I missed something. I've found posts about the solder at the fuel pump where the wires go into the pump and tapped/jarred that area best I can with no luck. I've also read others who get the same fuel pressure readings while running, are those correct numbers?

Any help anyone can give would be great, cause I'm lost and really want to trust this thing again. My KLR is great, but I miss my power.
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