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Author Topic: 99 gen 1 fuel pump and pressure regulator replacement?? now has second Issue?  (Read 1652 times)

Offline BillyBoyBusa

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 So What can i do to replace my 99 gen 1 fuel pump and pressure reg/
that is not avaible, or is it?
 I could only imagine plenty of you have had to do so.
I have ordered in a quantum pump and reg that don't match up.
 Any suggestions on the correct route to resolve my need ??
 a conversion?
Thanks.
BillyBoyBusa
« Last Edit: January 24, 2021, 08:12:43 PM by BillyBoyBusa »

Offline BillyBoyBusa

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Re: 99 gen 1 fuel pump and pressure regulator replacement??
« Reply #1 on: November 15, 2020, 01:34:45 PM »
So What can i do to replace my 99 gen 1 fuel pump and pressure reg/
that is not avaible, or is it?
 I could only imagine plenty of you have had to do so.
I have ordered in a quantum pump and reg that don't match up.
 Any suggestions on the correct route to resolve my need ??
Thanks.
BillyBoyBusa

Offline Nosgsx1300

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Re: 99 gen 1 fuel pump and pressure regulator replacement??
« Reply #2 on: November 17, 2020, 12:49:03 PM »
When I needed a pump for my 2000
Accel 74701 pump
Mallory regulator 29389 

regulator has risen in price by about $50 since I did mine 8 years ago

Pump fed me till 300 Hp
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2011 Loring 204.88mph "naked"
2015 Loring 220.01743 MPH Faired in fifth gear


Offline BillyBoyBusa

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Re: 99 gen 1 fuel pump and pressure regulator replacement??
« Reply #3 on: January 24, 2021, 03:27:50 PM »
I was able to get fuel  problem going , when it was last replaced the pump wire was pinched in the stock external pump housing  cover,
With that resolved and after riding a few times. A new issue has come up, while either hard acceleration after letting off the throttle or hard deceleration with no throttle, the motor shuts off, it starts back up with no issue, it even starts back while rolling.
I have installed a T I P BYPASS , to Eliminate Possibly a bad T I P sensor, because thatís how this problem was acting.
Boys i need some advice I am sure someone has had the issue ???

Offline BillyBoyBusa

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Re: 99 gen 1 fuel pump and pressure regulator replacement??
« Reply #4 on: January 24, 2021, 03:32:22 PM »
Thanks to NOSGSX 1300 for responding

Offline RansomT

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Re: 99 gen 1 fuel pump and pressure regulator replacement??
« Reply #5 on: January 24, 2021, 06:03:01 PM »
I would first slightly raise the idle and check for a vacuum leak.


The next involves a question.  When is the last time the valves were adjusted?
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Offline BillyBoyBusa

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Re: 99 gen 1 fuel pump and pressure regulator replacement??
« Reply #6 on: January 24, 2021, 08:12:17 PM »
 Thanks for the reply Ransomt,
I do have the idle up and have recently found a vacuum leak and a kinked vacuum line , corrected those but possible to have another I will use some spray and look.
As far as the valves they have not been done every since i have owned it and i have had the bike for a lone time, nor did the previous owner!
Its a crazy issue because i can be going 50-60-70 pull in the clutch and brake hard and the motor will shut off , Starts back up! on the other side iIwill be splitting lanes and accelerating hard and let off completely and the motor will shut off. That gets pretty interesting to say the least trying to get it restarted hauling ass between a couple of cars, sometimes having to coast over and stop on the side of the fwy at times its harder to get it started??
I am think about taking it in to Suzuki service and biting the bullet if i have to, but hoping more experienced tech types will have some advice that have cured these type of issue??

Offline BillyBoyBusa

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I got to love my title, Apprentice post whore, Right on Admin.LOL

Offline LVBUSA

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Vacuum leak, hmmm...

How about check kickstand switch, and t/o switch ?.

Check tension on your side stand , if it's loose or floppy it'll sure enough shut your motor down and then relax back into the closed position. Fires right up.

I'd check the tip over sensor also. They mimic power outage.

If all checks, considering your remarks, leak down test.
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« Last Edit: February 07, 2021, 04:44:06 PM by LVBUSA »
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Offline BillyBoyBusa

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Hey Thanks for the impute LVBUSA,
So i have installed a tip over Bypass from Siznit racing,  Kick stand seemed  a little floppy so I zip tied in the the foot peg, Still no luck.
Its driving me nutssss. I can literally be goin 50 and up and front brake hard and boom shuts off. hope its not a leakdown problem.

Offline BillyBoyBusa

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Any Suggestions for someone that is a good  Haybusa  Mech, 805, 818 area codes

Online Stainless1

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What else do you see... what does the dash do... have you looked for codes. 
When you try to restart does it just spin the motor or do nothing

Pull the ECU, unplug and replug... twice.. look at wires and male pins... if anything is growing green hair spray it with contact cleaner.

Inspect the wiring around the regulator... look for burned or dark color... unplug every connector you can see around the motor, inspect and re plug... repeat that step... look at male pins.... yes I really want you to do it twice... that will clean the tarnish from long term storage off of them.
Pull the ground wire off the back of the motor, clean terminal and mount spot with sandpaper... track it back a few inches and unplug and replug the single wire connector several times.
Look at the fuses near the starter solenoid, pull and plug at least twice.... same for connectors
Main fuse box, same same... pull and plug
If it is easy to duplicate it is easier to fix... the ones that are the shits are the ones that just pop up at the worst time...

Just thought of one more... after it is running unplug the Cam sensor and ride it to see if it does it... have seen them cause a motor to quit...
« Last Edit: February 15, 2021, 02:38:39 PM by Stainless1 »
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Offline BillyBoyBusa

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Right on Stainlees 1,
 Will do, Thanks for the tips.
 I am getting no Codes, I have noticed a pressure release sound coming from the gas cap.
when i shut the bike off, but its not new.;
 This problem is easy to duplicate happens a lot .
I can make it happen doing 45 down my street even.
I have wiggled every connection and wire and wire connecter on the bike.
 Its easy access to it all since most of the plastics are removed.
I will respond with the feed back after trying.
I have the bike mostly stripped down while working on figuring this issue out.
It is a way different ride with it stripped down.
 Any way response coming soon.
Thanks.
« Last Edit: February 15, 2021, 08:43:42 PM by BillyBoyBusa »

Offline RansomT

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Sounds like a collapsed or pinched vent tube.
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Offline BillyBoyBusa

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 Okay  my saga continues, appreciate  feed back , Stainless 1 and Ransom T
As  suggested I have unplugged plugged back in connectors every where and inspected all the plugs i can find, no issues there, When it dies there are no codes ,riding in dealer mode. unplugged the cam pos sensor after starting, no change,
inspected hose routing, for broken or pinched ,All good. i did pull the crankcase breather plug, Which i have never done , got a surprise on my floor, oil stunk like a mix between oil and fuel.
Still didn't help me. When the engine shuts off only see oil light comes on, engine starts right back up, some times takes longer, but usually starts right back up while still rolling.
still frustrated..

Offline TT

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i had kinda the similar problem with my 99 i could be going down the highway & the bike would just shut off, & then start right back up again and it got worse, it seemed like every time i hit a bump in the road it would shut off but start right back up again, what i found with my 99 was in the wiring harness where wires branch off to plugs & connectors suzuki uses these little useless brass crimp rings to make the connections, i had about 4 of them that had bad connections i soldered them all, had to cut open the harness to do it,  Try this raise your tank & start twisting the harness in differnt sections, twist hard & see if you get a misfire , i also found that the tps plug had a shitty connection i cut the plug & hardwired it
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Offline Nosgsx1300

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when My fuel pump was dying
I would be riding along and it would feel like it was nosing over a bit
then it would shut off and refire before I rolled to a stop

I think the filter screens were getting dirty
so that is when/why I replaced my fuel system
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2011 Loring 204.88mph "naked"
2015 Loring 220.01743 MPH Faired in fifth gear

Offline BillyBoyBusa

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Well, Thanks for the Tips.
We will know soon, My Busa is at Suzuki getting Diagnosed.
I could not wait to ride it much longer , Iam a Busa junky.
I will post the fix for the issues we have been discussing.
Billy Boy.

Offline BillyBoyBusa

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Well Then.
My bike has been at Suzuki for two weeks with no luck.
They have tested all the sensors, switches, Charging system...
They don't know what's wrong with it.
Now what???
I guess i will pick it up this weekend.
I read some of you talk about a guy you'll call MR Suzuki himself.
I need to talk to this guy.
Who is he???

Offline Oz Booster

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Going back over this, your cutting out problem started after replacing the fuel pump ?or was the pump not replaced after you found the pinched wire ?
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Offline BillyBoyBusa

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Oz Booster,

Your right, it was a pinched wire inside the external fuel pump housing. I freed it up and ran with it.
I am feeling the same way. After my local Suzuki dealer tested all the sensors, switches, and related systems they have no answers.
They are pointing at the ECU, but why only under hard breaking? Could it be inside the fuel pump housing? Is it time to replace the external fuel pump and housing with an inline fuel pump regulator and filter?
How would I get past the fact that the gen one fuel rail has no return at the end of it?

Thanks for the input,
Billy Boy Busa

Online Stainless1

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I would doubt it is the ECU... did they put a fuel pressure gauge on it, ride it and get the failure? 

Replacing one of the plastic tubes on the fuel rail if how you do a return... same piece to facilitate attaching a test gauge, there used to be a bunch of folks making those small parts... probably mostly replaced by folks that make new 1 piece rails.

Does the dealer have a test ECU to check?  What number is on your 99?  I could have one you could borrow if it comes to that... I have a stack and not sure which is which, but I suspect at least one is a 99.
I probably also have fuel rail parts, I just need to look for them.

Did the dealer give up and give the bike back to you?
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