fuel pump will not work - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 38 (permalink) Old 05-27-2019, 12:35 PM Thread Starter
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fuel pump will not work

my old fuel pump and my new one wont work it worked and ran fine last yr and then this yr it wouldn't start. I saw the fuel filter was dry but I get fuel out of the tank. I have a 1998 Vulcan classic 1500
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post #2 of 38 (permalink) Old 05-27-2019, 12:40 PM
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Hello, I had responded to your welcome thread, but here is a better spot for it...

You mentioned you replaced the fuel pump, and quoting one of my own mixups here, did you cross connect the lines? You know, hook the line from the tank to the outlet of the pump?

Have you tested for power at the connection to the fuel pump?

Do you have a service manual? If not, I would purchase or download one. Then you'll have access to all the wiring diagrams needed to troubleshoot your issue.
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post #3 of 38 (permalink) Old 05-27-2019, 07:17 PM Thread Starter
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I have a Clymer service - repair - maintenance book. I took pic of how old pump was hooked up and put new pump in as old was
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post #4 of 38 (permalink) Old 05-27-2019, 09:19 PM
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Double check your lines. You didn't mention if you used a genuine Kawasaki part or aftermarket, but on some aftermarket units, things can get crossed up. It's the simple things, like what angle the wires come out of the casing in relation to the fuel inlet/outlet... That can make it ~look~ correct by the picture, but not be correct.

It's handy to have a helper when doing these tests. Someone to turn the key on and off as you move about testing this connection and that one.

Can you hear (or feel) the pump running? It may only run briefly when you first turn the key on.

If you have a meter or at least a good test light and a helper, also verify that you have power coming to the fuel pump.

No power? Check the fuses next.

You can also try jumping 12v direct to the pump. There's another thread on here somewhere describing the process for that. If the pump doesn't run with direct power and ground, bad pump. Wouldn't be the first new defective pump I've seen.

Let's get this far and if it's still not working, we can move on from there...
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post #5 of 38 (permalink) Old 05-28-2019, 09:10 AM Thread Starter
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Ok I will look into that stuff when I get home from work
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post #6 of 38 (permalink) Old 05-28-2019, 06:55 PM Thread Starter
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ok so I took pump off and hooked it to battery it work but I decided to try old one and it worked too. I have a multimeter but when I read on here a post about testing for power going to pump I wasn't sure what setting to have it on since it said something about 10.85 was good did check the fuses under the seat by the battery and they all good but none was labeled fuel or fuel pump. im at a loss on this it should be simple to fix I would think
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post #7 of 38 (permalink) Old 05-28-2019, 08:58 PM
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Your multimeter should be set for "Volts DC", and at the first range over 12v. Without knowing which meter you have, I can't be more specific than that. I have several meters, and every one is a bit different, but functionally the same.

I went to download a manual to assist in helping you, and I'm showing options for both carb'd and FI models. To be sure, which one is yours?

Once I have that information, I'll download the appropriate manual and we can move on with troubleshooting
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post #8 of 38 (permalink) Old 05-28-2019, 09:48 PM Thread Starter
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My multi testers that I have. My bike is carb
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post #9 of 38 (permalink) Old 05-28-2019, 10:57 PM Thread Starter
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Hmm I posted but it didn't post lol. So my bike is carb. my multi meter is a china made one it has no name lol
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post #10 of 38 (permalink) Old 05-29-2019, 03:09 PM
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Okay, here goes...

First, I'm working from a manual for a 97 mean streak 1500.

For testing here, on your Micronata meter will probably serve you better. Set it to DC volts, 15

From the manual I downloaded, the fuel pump does not run when the key is on alone. The starter button must be pushed or the engine must be running.

Working from the bike side of the harness (not the portion on the fuel pump) let me know the results of these steps:

Check for voltage on the red, black, and black/white wire at the plus for the fuel pump. This has to be done while the starter button is being pressed. (remember I said you would need a helper?)

Verify continuity for ground on the black/yellow wire.

Since you've already tested your pumps, I dont have to go through a complete testing procedure.

The manual shows that the pump should run when power is applied to both the black/yellow and black, with green being the ground.
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