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Discussion Starter #1
Ok - long story short, scored a low mile V92C with < 2K miles. Took it to the dealer and had the 30K service done to ensure everything was in order...New Plugs, New Battery, front forks seals & fluid, front and rear brake fluid, new K&N Air Filter, oil & filter etc.

Bike ran beautifully on it's maiden voyage this morning...for the first 5 miles...then it all went south. Bike got to 50 mph and then all of a sudden started bucking and I had a dead throttle. It stayed running long enough for me to limp into a parking lot where I turned it off and let it sit for a while...restarted it and it ran ok for a mile and then it went back to dead throttle and barely running...until I finally got it home...The symptoms are the same as the when I had to replace a TPS on my Kawasaki Vulcan 1500.

So: My thoughts are that I've got a new battery and 12.8v at idle and 14.4v on the throttle, new plugs etc. so it's not spark; new air filter so not air, exhaust is fine...which leaves the fuel.

The bike sat for who knows how long so I added a full tank of new fuel with seafoam because the tank probably had some rust on the inside that I couldn't see,

I'm thinking either the TPS, clogged fuel filter or fuel pump?

Any other ideas?

Thanks,
Frank
 

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The bike sat for who knows how long so I added a full tank of new fuel with seafoam because the tank probably had some rust on the inside that I couldn't see,

I'm thinking either the TPS, clogged fuel filter or fuel pump?
This sounds very likely. If there is rust in the tank, it may need to be Kreemed http://www.kreem.com/fueltankliner.html

If it runs fine for a bit then dies, then starts after you let it rest a bit, it's probably starving for fuel.
 

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So it starts all the time?
You can go to auto store and rent a fuel pump tester. You should have 50 psi. try a couple times. Try reseting your TPS.
Key on, switch on, engine off

Slow 5 count rotate throttle from closed to wide open

Hold throttle wide open for slow 5 count

Let throttle SNAP shut/closed

Cycle kill switch (off then on)

Start bike, and enjoy the ride
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So it starts all the time?
You can go to auto store and rent a fuel pump tester. You should have 50 psi. try a couple times. Try reseting your TPS.
Key on, switch on, engine off

Slow 5 count rotate throttle from closed to wide open

Hold throttle wide open for slow 5 count

Let throttle SNAP shut/closed

Cycle kill switch (off then on)

Start bike, and enjoy the ride
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That doesn't reset your TPS. All that does is re-establish the baseline for zero throttle as a starting point.
 

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Discussion Starter #5
Thanks for the responses. I talked to the dealer who did the service and he suggested the fuel pump and filter first. Said that he checked the TPS voltage during the service and it was within spec. If that doesn't solve it, then I'll go for a new TPS.

He also said that it was unlikely to be the "Inside the tank fuel filters" since at 50 psi, they will blow anything through those high pressure filters.

So, I'm going to start with draining the tank and replacing the outside fuel filter and testing the fuel pump. If that doesn't work then I'll reset/replace the TPS.

Thoughts?
 

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Unless I have a severe misconception, your dealer is wrong on the bag filters inside the tank. The pump has to pull the fuel through them, and it cannot create any discharge pressure if they plug up.

My knowledge of these fuel pumps and filters is simply from reading the manuals and reading on this and similar sites, watching witchdoctors fuel pump removal video, and past experience with what appear to be very similar systems. So take my input with a block of salt.

But I think it would only take a teaspoon or less of the rust, varnish and paint bits to plug up those bag filters. And it would not be hard to do with a low mileage bike that sat a long time.

I would approach the issue with an open mind. Checking fuel pump output pressure is a great first step.
 

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Does a 2001 have the internal filters or the 2 small inserts in the "snorkels" at the bottom back of the tank ???
 

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Well, I did have some misconceptions.
I downloaded the parts and service manual for your bike, and took a quick look.

It does not have bag filters, it has what appears to be screen tubes stuck in the tank outlet lines. As long as you are removing the tank they should be easy enough to pull and clean.

The manual also warns that if your pump runs without flow it will soon be overheated and damaged.

Your system is quite a bit different than the later versions I was vaguely familiar with.

But I would still clean the suction pre filters or screens and check to see what comes out of your tank.
 

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Discussion Starter #9
Thanks to all for your responses...I have a shop manual and it talks about the two small filters inside the "fuel pipes."

It states that the "pre-filters can be cleaned and reused if not physically damaged....It says to "grasp pre-filters and remove from fuel pipes...wash in solvent from outside in and dry with shop air..."

So, I purchased all three items for the job...to rent the fuel pressure meter and take it all apart to measure was more than a PITA than it's worth...so I'm just going to go ahead and put in both a new fuel pump and fuel filter while I have it all apart.

Purolator F67221 from Advance Auto: $11.89
Durolast Throttle Position Sensor TPS-140 from Autozone: $26.99
Airtex E2000 Fuel Pump from Autozone: $83.99

With tax and military discount it was a total of $127.79. Will keep posting as we make progress.

Thanks again.
Frank
 

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Frank
I would ask Rylan at the Vic shop if that fuel pump is any good.
You might be doing a lot of work for something will not last or work.
 

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Discussion Starter #12 (Edited)
The Right Answer Was...

:) For those of you that voted Fuel Pump/Fuel Issue...CONGRATULATIONS...you were the winner!

Spent 1/2 the day cleaning the fuel tank out (Boiling water, sump pump and draining, added etching acid, repeat several times)..Replaced the fuel pump and fuel filter and reset the TPS... runs beautifully! I was hoping that I didn't have to replace the TPS, and I'm going to only ride it locally for the next week until I feel confident that I fixed the problem.

The Airtex Fuel Pump e2000 was the direct cross reference part for the pump that was taken out...It still works, so I'll keep it just in case. Thanks for everyone's help and responses.

Frank
 
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