Newbie need help.

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stugts1000
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Newbie need help.

Postby stugts1000 » Wed Jun 15, 2016 1:23 pm

Hello everyone,
I am need of your help. I am the proud owner of a 1996 GTS which wont start. I have traced the problem to no feed to the fuel pump which is controlled by the ECU. The part number of the one fitted to the bike is 4FV-8591a-00. I have tried to find a replacement unit but cannot find one anywhere. I have tried to find someone to repair but again cannot find anyone.
When I have looked at part numbers for alternatives 4bh-8591a-00 was fitted to earlier models and when I looked at the wiring looms numbers they have never changed all through this models life so would I be right in thinking that an earlier one would possibly work?
Any assistance any one can give would be very welcome.

Kind Regards

Stuart

lewisjjp
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Re: Newbie need help.

Postby lewisjjp » Thu Jun 16, 2016 9:35 am

The 4bh prefix will work ok, 4FV was the prefix used for different countries eg Austria, however, I would be surprised if the ECU is faulty as they are very reliable. Do you have a full Yamaha manual?

OmegaChassis
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Re: Newbie need help.

Postby OmegaChassis » Thu Jun 16, 2016 12:13 pm

Try the starter solenoid first, I am sure this provides a feed to the fuel pump? These tend corrode over time. If that does not work and you still think it is ecu. I have a few spare one's you can try.
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lewisjjp
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Re: Newbie need help.

Postby lewisjjp » Thu Jun 16, 2016 6:05 pm

The fuel pump is fed from the EFI relay which is the middle relay on the left hand side. You need to go through it methodically though, check your fuses, battery voltage, main switch, engine stop switch as all these items stop you getting a voltage at the pump and I assume you have checked that. Hope that helps.

stugts1000
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Joined: Tue Jun 14, 2016 8:17 am

Re: Newbie need help.

Postby stugts1000 » Thu Jun 16, 2016 10:38 pm

Thanks for your help. Will check it out and will let you know how things check out.

Stuart

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Arno
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Re: Newbie need help.

Postby Arno » Fri Jun 17, 2016 5:38 pm

There are two possible reasons, the starter relay is defective, or injectors do not work, so that no fuel is injected. Try out whether behind the fuel filter if gasoline pumped.
Injectors can be cleaned in an ultrasonic bath.

stugts1000
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Joined: Tue Jun 14, 2016 8:17 am

Re: Newbie need help.

Postby stugts1000 » Wed Jun 22, 2016 10:14 am

I just thought I would let you know that the bike is now running again. Fault was a poor connection to fuel pump relay.

My next repair is I have the front suspension squeak. Do any of you kind people have any suggestions as to the best way to approach this job as dont want to mess up the suspension settings. Obviously mark it up and put everything back as it was seems the most obvious answer!

Thanks for any help.

Stuart

devonrider
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Re: Newbie need help.

Postby devonrider » Wed Jun 22, 2016 12:39 pm

stugts1000 wrote: My next repair is I have the front suspension squeak. Do any of you kind people have any suggestions as to the best way to approach this job as dont want to mess up the suspension settings. Obviously mark it up and put everything back as it was seems the most obvious answer!

Thanks for any help.

Stuart


Yep.
I got the squeak too.
Think of that as a cry for help.
My bearings / ball joints were all OK, but would not have been if I'd left it for much longer.
My squeak was from the uppers "A" arm, but I decided to just strip it down and do everything.

Image

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Devonian
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Re: Newbie need help.

Postby Devonian » Wed Jun 22, 2016 2:21 pm

The only adjustment you can mess up is the left side pivot bolt for the upper A-arm. You can get the A-arm out without undoing this bolt (you just remove the nut from the "inside" end) so you will not have to disturb the adjustment.

Here's a cut and paste from the old ADVRider post I linked to a couple of weeks back:

I just completed a quick inspection and lube of the front suspension in response to hearing a slight squeak at times. Reports abound of finding one or both of the upper suspension arm bearings corroded away so the old girl has been parked for a few weeks so as not to cause any further damage while I got around to tackling the project.

It turned out to be a bit easier than expected. Not being used to working on a fully-faired motorcycle, removal of all the crap necessary just to get to the bits I was interested in was the main obstacle.

Here are some notes and photos:

Removed the four allen-head cap screws holding the front of the fender and the six bolts for the rear. Removing all the allen screws holding the brackets, etc., turned out to be unnecessary.
Image

After removing the front wheel, bellypan, lower fairing panels, rubber flap over the A-arm and rubber cover over the right side bearing (right side of the bike, left side of these photos,) plus detaching the steering tube and tying it up, I could get at the bearing bolts. A long extension allowed a straight-shot at the nuts.
Image

The A-arm is set up so the left side can be adjusted left-to-right (the camber adjuster) and the right slides on a bearing sleeve with no sideways thrust control.

The right side bearing bolt pulls out of the frame to release that end of the A-arm. The left bearing is a spherical bushing (basically a captured ball with a bolt through it) so once you remove the alignment sleeves, the A-arm can pivot out enough to slide it off the left side pin (which remains in place). It was necessary to pull the brake hose and ABS sensor wires out of their clips underneath the arm.
Image

The right side needle bearing showed some signs of wear and the grease was dry - but it was tight and spun freely and the seals looked ok so I simply cleaned and re-greased it.
Image

Yamaha recommends a moly grease although that did not look like what was in there. I happened to have some on the shelf.
Image

The spherical bushing had a trace of red, indicating that perhaps the bearing seals are not as water-tight as they should be and from the wear is almost certainly the source of the "squeak!" - Just as expected. Strangely, this side is not also protected by a rubber boot.

Despite its appearance, the bearing appeared tight and smooth so I rotated it around to clean it in-situ and repack the groove with grease
Image

When retorquing the left pivot bolt nut, I had to hold it from the outside with an allen wrench to prevent the bolt from turning, thereby messing up the camber adjustment.

I'm a great believer in "if it ain't broke, don't mess with it". As the upper and lower ball joints supporting the knuckle arm were both moving freely with no play when gently levered and the boots were in good condition, I left those alone.

With the lower suspension arm suitably supported, the shock could be unbolted. The lower eye is another spherical bushing and was in perfect condition. I added a little grease and put it back together. As there was no discernable play in the upper eye, I left that alone too.
Image

I removed both the lower suspension arm bearing pivots by undoing the castellated nuts and pulling the pivot bolts out. The bearings on both sides appeared to be sealed units in great shape with no signs of water intrusion, free play or roughness, so they went back together with no action taken.
Image

Reassembly was a reverse of the dis-assembly process. I pulled some of the attachment "tits" off the A-arm rubber cover while removing it, but it proved easy enough to hold in place with cable ties through the existing holes.
Image

All that remained was to check everything was back together, brake hose clipped back in place, bolts torqued, etc., then replace all the bodywork. There are so many screws and bolts holding this all on but after doing it a few times now, it doesn't take long.
Image

:clap: Initial testing seems to show that the "squeak!" has gone. :clap:
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stugts1000
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Joined: Tue Jun 14, 2016 8:17 am

Re: Newbie need help.

Postby stugts1000 » Wed Jun 22, 2016 3:04 pm

Hi Thanks for your help. Will have a look at it over the weekend.

stugts1000
Posts: 6
Joined: Tue Jun 14, 2016 8:17 am

Re: Newbie need help.

Postby stugts1000 » Tue Jun 28, 2016 3:32 pm

Carried out the greasing of the front suspension arm at the weekend, not as difficult to do as you first think, maybe two hours work in total.The bearings were both dry and after a good clean and regrease, everything is now fine and squeak has disappeared.
I now have to look into only being able to see my hands in the mirrors after fitting handle bar conversion! If any one has a fix or ideas please let me know. Im thinking bar end mirrors but would prefer not to.

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Arno
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Re: Newbie need help.

Postby Arno » Fri Jul 01, 2016 7:53 am

The best mirror for a handlebar modification are the mirror of the BMW R 1100 S.
With the appropriate adapter plate this match without change in two of the three holes of the GTS. The third bore can be used for the attachment of the adapter plate.

MTK
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Re: RE: Re: Newbie need help.

Postby MTK » Thu Jul 07, 2016 4:14 am

stugts1000 wrote:Hello everyone,
I am need of your help. I am the proud owner of a 1996 GTS which wont start. I have traced the problem to no feed to the fuel pump which is controlled by the ECU. The part number of the one fitted to the bike is 4FV-8591a-00. I have tried to find a replacement unit but cannot find one anywhere. I have tried to find someone to repair but again cannot find anyone.
When I have looked at part numbers for alternatives 4bh-8591a-00 was fitted to earlier models and when I looked at the wiring looms numbers they have never changed all through this models life so would I be right in thinking that an earlier one would possibly work?
Any assistance any one can give would be very welcome.

Kind Regards

Stuart

I had a GTS that sat for years. Rust built up in the tank an clogged the fuel line. No fuel pumped into the injectors. I reconditioned the tank cleaned the lines and replaced the filter. That did the trick for me.

lewisjjp wrote:The fuel pump is fed from the EFI relay which is the middle relay on the left hand side. You need to go through it methodically though, check your fuses, battery voltage, main switch, engine stop switch as all these items stop you getting a voltage at the pump and I assume you have checked that. Hope that helps.


Arno wrote:There are two possible reasons, the starter relay is defective, or injectors do not work, so that no fuel is injected. Try out whether behind the fuel filter if gasoline pumped.
Injectors can be cleaned in an ultrasonic bath.



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