| Author | Message | ||
     Rays |
OK, so I have now had my '09 XT join the ranks of the 'intermittent fuel pump fuse blowers'. I was lucky not to get hit at the time as I had just taken off from the lights and the car behind me did not expect a sudden slow-down. Anyway, I diagnosed a blown fuel pump fuse fairly quickly and popped in the spare and away it went again. I continued on to work OK and then the 25 miles back home without further issue but my trust level has now gone right down. I measured the fuel pump current at start up and it draws 5 amps - the actual spec in the manual is 6 amps so I doubt I would get much of a hearing for a replacement at this stage. Of great interest is the comparison to my '06 X that only draws 3 amps for the initial fuel pump start-up. The '06 manual also shows a spec of 6 amps. Has anyone else measured the current draw of one of the later fuel pumps? Across the forums there are quite few reports of '09's blowing fuel pump fuses so it would be good to get a clearer picture of the root-cause. | ||
| Ronbob43 |
Mine always happened on HOT days with a low level of fuel in the frame. Since it was replaced under warranty and I added a RSS the problem hasn't resurfaced. I do gas up sooner on hot days now to keep the demons at bay. | ||
| Sirvait |
Well it happened to me again today for the SECOND time. I was also lucky, doing 75mph in rush hour. Fuel was over half full though. 90 degrees outside today. | ||
| Sirvait |
looks like all the grounds are good. I'm going to let the Techs have a crack at it. It there a new pump out? Superseded part# | ||
| Mesafirebolt |
Mine was doing that, Pulled the pump and found the wires were chaffed (Inside the tank on the pump). No biggie, I fixed the insulation and back on the road. This is a known issue, you might want to check it out. It can happen occasionaly just every once in a while like mine did, then the wire got bare enough to short itself out with a hard fail. That was the only way I was able to diagnose it. | ||
| Jacrex1 |
I'm putting back together a wreck XB9, I thought everything was done and tried to start it . no hum from the fuelpump . I pulled the pump out , no chaffed wires, but both wires on the pump are hot . when I remove the neg. wire and ground the pump. the pump runs ! I checked the fuses and the hot ones are all good. noted the horn doesn't work and that the ignition switch doesn't go to lock position . I will check today to see what fuse is for the horn and if its getting power . I'm disabled so progress is slow . but it's something to do ! I have put a new ECM from a 2006 , the bike is a 2004 so this might be an issue too . | ||
| Froggy |
Jacrex1, the 2004 XB9 used DDFI1 fuel injection, the 2006 used DDFI2, the ECMs are not compatible with each other. | ||
| Jacrex1 |
ok..i will switch back ! thank you ! | ||
| Spotts |
My 2009 XB12XT did it twice, hot days, low fuel. I requested the dealer install a new pump, suggesting the 10 models were updated (rumor from thread here). Dealer had new pump waiting when I brought the bike in for the 1K service. Installed, warranty, no problems in the 1500 miles since. If under warranty, I recommend asking for a replacement. Too dangerous to mess around with. | ||
| Froggy |
Mesafirebolt, the fuel pump issue with the chaffed wires was only on 05/06 bikes, the fuse issue on the 09's is different. 2010's have a new type of fuel pump and it is not compatible with previous years without 2010 ECM programming. The fuel pressure is regulated by the ECM on it. | ||
| Swampy |
I have a fuel pump ground pin problem....I assume it is aground pin as it is for the black wire, the pin is shorter and burnt looking and the socket has a little bit of metal protruding out of the receiver. Are the pins available? upper right  and the receptical? upper left  Part numbers? work around parts? Thanks | ||
| Rays |
Swampy, that looks like a Deutsch connector but my '09 Electrical manual lists it as 4-place AMP Multilock. I will have a look at my '09 later today and let you know what the story is - if it is Deutsch then the parts are very available from sources other than HD because they are commonly used in lots of applications. I will also have to have a look at the '09 wiring diagram but I recall an earlier XB problem where the fuel pump earth wire was smoking during attempted engine starts. That was related to the starter not getting a good ground via the upper tie-bar ground lead if I recall. I am only throwing out a wild guess based on the overheated ground wire. The power for the fuel pump is directly fused so shouldn't allow enough current to burn the pins. However, having said that the connector looks very dirty and these sealed connectors are normally immaculate inside so is that dirt or carbon from the burning or oil that is visible? It is also possible that a dirty connection will set off a knock-on effect of resistance, heat, carbon, more resistance..... I'll keep you posted but wouldn't travel anywhere with a fuel pump connection in that condition unless you are feeling very lucky.  Swampy, I just read your other post in the BB&D section so you are onto the tie-bar ground already so my info is old news - sorry. (Message edited by Rays on October 21, 2011) | ||
| Rays |
Swampy, I just checked my '09 XT and these are definitely Deutsch. The male plug (female sockets) on the pump is a DTM06-4S so the Female on the loom will be a DTM04-4P. I also see that they have used blue dielectric grease on these so some of what appears to be grime in your photo is probably that grease? This link is one company that I have seen on the web that advertises these - at least they have a good online view that you can relate to. The good news is that Deutsch connectors in this size can use solid pins and sockets that can be soldered - the crimping tools for Deutsch are really expensive for one-off jobs so if you can solder well (or know someone who can and can be bribed with beer) then that would be my preferred approach. Back in the day when I worked on older aircraft all of the connectors were soldered and are very reliable connections when done correctly. These Deutsh connectors have mechanical relief on the wires via the sealing rubbers in the backshell and lend themselves to soldered pins. http://www.deutschconnector.com/products/deutsch_d tm_4-way_connectors.html | ||
| Swampy |
I found the pins at the local H-D dealer! They had the male side but had to order the female side, I now will have 9 extra ones incase anybody needs one! I will drink another beer, change my clothes and go clean up the connector and solder the thing on. I tried a bunch of auto supply places but they only had larger pins that use the spring clip to hold them into place in the connector. I did have a problem with the engine grounds, the first indication is it would not crank the engine unless the clutch was pulled in, I'm guessing I will need a throwout bearing in the near future if not a clutch cable. Thanks for everyones help over here, I usually do not post on the big bike side as I am always over on the Thumper forum helping out. |
