Repair / Fuel system
Fuel system
Problems, repairs and parts for the fuel system.
Problems
- No fuel reaching the carburettorDo not ride
- Fuel pours out of the carburettor overflow pipeDo not ride
- Choke is stuck on or will not workRide with care
- Unstable idle after cleaning or battery disconnection (fuel-injected)Ride with care
- Engine warning light (check engine, MIL) is on or flashingRide with care
- Fuel cap is stuck, leaks or will not lockRide with care
- Fuel gauge reads wrong or does not moveOK to ride
- Fuel is leaking or drippingStop now
- Fuel pump whines loudly or runs all the timeRide with care
- No buzz from the fuel pump when the key is turned onDo not ride
- Strong smell of fuel around the bikeDo not ride
- Engine stops and only runs on reserve or after a restRide with care
- Fuel injector suspected blocked or leakingRide with care
- Rust or flakes inside the fuel tankRide with care
- Old or stale fuel in the tankRide with care
- Engine stops after a few kilometres and the cap hisses when openedRide with care
- Water or dirt in the fuelDo not ride
Repairs
- Check the fuel tap, lines and flowHome workshop · 20 to 45 min
- Replace the fuel filterHome workshop · 20 to 40 min for an inline filter; in-tank filters are workshop jobs
- Check the carburettor float and needle valveHome workshop · 30 to 60 min with the carburettor off
- Clean the carburettorHome workshop · 1.5 to 3 h
- Clean and lubricate the fuel capRider job · 10 to 20 min
- Check the fuel tank ventRider job · 10 to 20 min
- Drain old or contaminated fuelHome workshop · 30 to 60 min
- Remove rust from a fuel tankWorkshop job · Assessment 20 min; treatment 1 to 2 days at a workshop
- Check the fuel pump (fuel injection)Home workshop · 15 to 45 min for the home checks
- Check the fuel injectorWorkshop job · 10 min for home checks; 1 to 2 h at a workshop
- Check the choke or starter valveHome workshop · 20 to 45 min
- Clean or replace the air filterRider job · 15 to 40 min (estimate, plus drying time for foam)
- Bring a bike back into use after storageHome workshop · 2 to 4 h
- Clear a flooded engineRider job · 10 to 30 min
- Check the engine oil levelRider job · 5 to 10 min (estimate, includes warm-up and settling)
- Change the engine oil and clean the strainerHome workshop · 40 to 60 min
- Adjust the choke cableHome workshop · 15 to 30 min
- Lubricate control cablesRider job · 20 to 40 min
- Read engine fault codes (fuel injection)Home workshop · 15 to 30 min
- Check the engine sensors (TPS, MAP, temperature)Workshop job · 10 min for home checks; 30 to 90 min at a workshop
- Test the fuel level senderHome workshop · 20 to 30 min for checks on the bike; 1 to 2 h if the sender is removed
- Check fuses and relaysRider job · 10 to 30 min
- Clean and seal electrical connectorsHome workshop · 15 to 45 min
- Clean and tighten earth connectionsHome workshop · 20 to 45 min
- Check power to the instrumentsHome workshop · 20 to 40 min
- Find a wiring faultHome workshop · 30 to 90 min
- Measure fuel consumptionRider job · 2 to 3 tanks of normal riding
- Test and charge a 12 V batteryHome workshop · 15 min to test; charging takes many hours
- Test the engine stop switchHome workshop · 20 to 30 min
- Test the ignition pick-upHome workshop · 20 to 30 min
- Check the oxygen sensorWorkshop job · 10 min for home checks; 30 to 60 min at a workshop
- Diagnose a suspected CDI or ECU faultWorkshop job · 1 to 2 h assessment
- Find an intake air leakHome workshop · 20 to 45 min
- Read a spark plugHome workshop · 10 to 15 min, plus a short ride
- Reset the idle after throttle body workWorkshop job · 15 to 45 min at a workshop with the right tool
- Clean the throttle bodyHome workshop · 30 to 60 min
- Adjust throttle free playRider job · 10 min
