Squashed fuel return pipe !! - Kawasaki Forum :: KawasakiWorld.com
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post #1 of 35 Old 10-09-2016, 08:52 AM Thread Starter
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Squashed fuel return pipe !!

I looked for the old thread of mine about fuel pump fail ,could not find it ,

so quick up-date , new walbro pump installed and a fuel filter sytec under the tank ,it is flow rated and seems to be ok , but dyno man said i have big issues with fuel pressure ? It still pulled 175 bhp 92 lbs-ft but down on last years same dyno numbers 5 bhp and 6 lbs-ft of torque ,down. i have since noticed that my fuel return pipe was getting squashed slightly when tank goes back down ,which i think may have been the problem ?
Anyway the bike runs fucking real bad ,i only just managed to get it home last week ,throttle was very on/off ,you had to feather the throttle to just keep it rolling !!
No FI light ,it starts but as soon as you touch the throttle it revs and then cuts out ! could it be the pressure sensor ?
I have re-connected the original ecu (un-plugged PC5 ) no difference ?
Getting pissed off now , i have 2 new tyers to destroy and winter is here over £100 for a new pressure sensor !!
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post #2 of 35 Old 10-09-2016, 10:19 AM
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map sensor?
a restricted or kinked return line would make it run terrible.

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 249.5 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #3 of 35 Old 10-09-2016, 10:32 AM Thread Starter
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map sensor?
a restricted or kinked return line would make it run terrible.
so could i have damaged the map sensor ?

I have the tank slightly lifted so my hoses are all good ,but still runs the same !
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post #4 of 35 Old 10-09-2016, 12:25 PM
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Im not sure what a map sensor has to do with fuel pressure, but if you had it hooked up wrong (like to the tps plug) it could be causing the bike to run poorly or not at all.

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 249.5 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #5 of 35 Old 10-09-2016, 12:26 PM
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FYI the bike doesnt/cant monitor fuel pressure, its done mechanically, and if theres a problem, the ecu doesnt know

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 249.5 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #6 of 35 Old 10-10-2016, 08:55 AM Thread Starter
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Im not sure what a map sensor has to do with fuel pressure, but if you had it hooked up wrong (like to the tps plug) it could be causing the bike to run poorly or not at all.
No all connectors are where they should be ?

Does anybody know what the symptoms are for a failed or failing pressure sensor ?

I am not very competent when it comes to electrics on newer bikes (FI) !!

it runs so shit i can not even take it to my machanic friend !!!!
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post #7 of 35 Old 10-10-2016, 09:54 AM
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Andy, have you removed the suspect pipe and checked it is ok?
Its very easy and ridiculously cheap to change and would at the very least eliminate it.
Are you 100% sure new pump is good and the filter you have used is flow rated at 165+ lph?
Is the exterior Walbro pump below or above the outlet of the fuel tank?
Im suffering a similar cutting out problem since refitting my motor recently and feel your pain. Fortunately I have fault light so can diagnose. I shut the door on it for my sanity back in my garage tomorrow.

Good luck. Just go backwards and eliminate . Its soul destroying but when you solve it you will be happier than a sand boy!
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post #8 of 35 Old 10-10-2016, 10:39 AM Thread Starter
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Andy, have you removed the suspect pipe and checked it is ok?
Its very easy and ridiculously cheap to change and would at the very least eliminate it.
Are you 100% sure new pump is good and the filter you have used is flow rated at 165+ lph?
Is the exterior Walbro pump below or above the outlet of the fuel tank?
Im suffering a similar cutting out problem since refitting my motor recently and feel your pain. Fortunately I have fault light so can diagnose. I shut the door on it for my sanity back in my garage tomorrow.

Good luck. Just go backwards and eliminate . Its soul destroying but when you solve it you will be happier than a sand boy!
Cheers for your comments dave , I also walked away from it saturday i changed the fuel pump relay because it was all green and corroded ,no difference !, i think i will put the whole system back to standard and see what happens !? also my walbro pump is in-tank ,but the filter is now outside the tank (underneath the tank) and it is flow rated sytec re-useable one 200 + lph ,i think the squashed return fuel pipe under the tank caused the high number readings at the dyno ? but it still pulled well and had 175 bhp , but it was not 100 % ,but since the dyno approx 100 miles it has just became worse and now is un-rideable ..... the joys of zx12r ownership
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post #9 of 35 Old 10-10-2016, 10:58 AM
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Quote:
Originally Posted by andy1965 View Post
No all connectors are where they should be ?

Does anybody know what the symptoms are for a failed or failing pressure sensor ?

I am not very competent when it comes to electrics on newer bikes (FI) !!

it runs so shit i can not even take it to my machanic friend !!!!


WHAT pressure sensor?

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 249.5 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #10 of 35 Old 10-10-2016, 11:07 AM Thread Starter
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WHAT pressure sensor?
air pressure sensor , or atmosheric sensor ? or could my throttle sensor ?

sometimes i wish i could go back to a set of smoothbores and listen to that lush sucking sound
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post #11 of 35 Old 10-10-2016, 11:27 AM
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any sensor on the bike can make it act up if its not working.

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 249.5 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #12 of 35 Old 10-10-2016, 11:34 AM Thread Starter
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Originally Posted by KZScott View Post
any sensor on the bike can make it act up if its not working.
Yer i sort of worked that one out !
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post #13 of 35 Old 10-10-2016, 03:18 PM
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is there any chance that some crap got in the pressure relief valve if it has your pump will still deliver full flow but low pressure good luck Craig

if anything goes wrong check the battery
B1 black and "GOLD"
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post #14 of 35 Old 10-10-2016, 10:30 PM Thread Starter
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is there any chance that some crap got in the pressure relief valve if it has your pump will still deliver full flow but low pressure good luck Craig
the pump has a round proper filter on the in-let end ,and then i have a sytec filter on the out-let end before the fuel reaches the throttle bodies , so i can not see any shit getting through both filters ?
i think like dave said , re-check everything i have done ,i will have another look at it tomorrow ...... very frustrating !!!
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post #15 of 35 Old 10-10-2016, 11:24 PM
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As a test bypass both filters and also check the in tank return valve.
You could put a bolt in the tank and the pipe with the valve into a container so you can see fuel is returning and flowing.
My money is on the intank filter ...
You dont need two filters.
Good luck. Let us know :-)
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