2008 Fuel Pump - How to check power at connector?

[benwiggin2]

Allright boys and girls Happy New Year. It's been quite a while since I've visited here. That usually means there have been no problems, right? Over the weekend I was stranded for the second time in over 6 years on my beloved 08 TE 510. Thankfully it was the last ride on the last day of a 5 day So Cal desert trip, and I was on a dirt road instead of open desert like we had been most of the time. Anyway I'm asking if anyone can tell me (or dig up an old thread) on how to confirm there is power making it to the fuel pump. I have spark. But when key and ignition are enabled I no longer hear the fuel pump. Replaced all fuses. Bike turns over and has spark. Tank is off but the fuel pump still in tank. Is there any way to use a meter and confirm power to fuel pump? Thanks in advance for your replies!

Obligatory bike pic....

 

[Trenchcoat85]

sure... pierce the wire (gently) with a safety pin or needle- making sure it can't touch anything else. test the voltage from ground to the pin. Nothing? try the other wire (it's the red one, IIRC).

good luck.

 

[benwiggin2]

So there are 4 wires on the connector though. Is only one of them for power?

 

[OlderHuskyRider]

So there are 4 wires on the connector though. Is only one of them for power?

Yes, only 1 is for power.

Get a wire and touch it to the battery positive post, and plug the other end into the power for the pump, it should spin continuously. If it doesnt, its frozen

 

[OlderHuskyRider]

You'll need another wire for grounding as well

 

[benwiggin2]

Thanks guys. Trying to avoid guessing on which wires are ground and which is power. Can anyone identify the 4 wires on the attached schematic? 35 is the fuel pump. I'm hoping to confirm there is power reaching the pump. Should I just use process of elimination?

 

[268fords]

Good to see your both still around Benwiggin and olderhuskyrider. I can't get the wiring schematic to upload or the pic of the wires. If the pump checks out, check the handlebar switch too. Hopefully this will be an easy fix for you. Happy new year.

 

[OlderHuskyRider]

Green with red stripe is power, Blues are grounds

 

[benwiggin2]

Trench, OHR, 268- thanks for chiming in. Will hopefully update after work today....stand by.
Do we have a dedicated plug and play fuel pump relay?

 

[Trenchcoat85]

green/red: +12 for fuel pump
blue: ground for fuel pump
white/yellow: +V for fuel level thermistor (voltage may be lower then +12; like +7v on a empty tank)
blue: ground for thermistor

It doesn't look like you have a "dedicated" relay, but #38 is a relay that powers only the fuel pump, coil #23, injector #6, ...and #31 which is... I dunno.

 

[benwiggin2]

Ok, so...per above post(s) my meter reads 13.25 vdc when positive lead of meter is inserted to "green/red: +12 for fuel pump" and the negative lead is grounded to frame. Could not reproduce the readings when negative lead was inserted to the blue ground though- which seems odd to me...

 

[Trenchcoat85]

either blue wire? ...yeah, that's seems weird. lemme take a look at the diagram and I'll be back in 5 mins


....nope, you should be grounded. with the power OFF (and the fuel pump still plugged in.... right?) whats the resistance from frame ground to either/both of the blue wires (I'm looking for a number like 0 or 0.7ohms on your DIGITAL meter, almost any scale)

also: you may have found your problem.

 

[R_Little]

Bad ground?

Bike is a 2008. might be a good time to remove the pump to insect and change filter.

Just pull tank empty it in a gas can. Pull out 6 screws and remove.

These pumps and filters are a weak link in an otherwise reliable bike.

 

[benwiggin2]

So this issue turns out to be broken spade connector on the fuel pump. Also broken off was the thermister from its mount and its orange wire too. I'm unplugging the thermister assembly, don't need low fuel light, have a raw IMS tank to see fuel levels. Just need to research the best option for replacement fuel pump....I'm leaning towards this:
http://www.highflowfuel.com/i-23901...usqvarna-te-510-tc-510-txc-510-2008-2010.html

Honestly though...the stock wiring on this bike is in bad shape. All the years, miles, vibrations stack up in the back of my head when I'm out in the middle of nowhere. This bike has taken me lots of places but there's only so much you can carry or fix in the field...

 

[Trenchcoat85]

So this issue turns out to be broken spade connector on the fuel pump. Also broken off was the thermister from its mount and its orange wire too. I'm unplugging the thermister assembly, don't need low fuel light, have a raw IMS tank to see fuel levels. Just need to research the best option for replacement fuel pump....I'm leaning towards this:
http://www.highflowfuel.com/i-23901...usqvarna-te-510-tc-510-txc-510-2008-2010.html

Honestly though...the stock wiring on this bike is in bad shape. All the years, miles, vibrations stack up in the back of my head when I'm out in the middle of nowhere. This bike has taken me lots of places but there's only so much you can carry or fix in the field..

wow, good detective work Ben. do you think that the broken thermistor was knocking around and broke the spade off (I'm assuming here that it's the male spade, embedded in the pump, that broke)?

Also, I've never heard of that thermistor bracket breaking- I wonder if they're related; like something else was bouncing around in there. [edit: oops, looks like I was wrong; this thread from 8 years ago shows a broken bracket. Also, I noticed that on my fuel pump of the same style the bracket has a hairline crack in the same place.]
http://www.cafehusky.com/threads/2008-te-510-low-fuel-light-not-working.1229/#post-23807
good for you for coming back with your findings- it'll help in the future.

That pump looks perfect (although I'd go with a $15-19 ebay personally... I'm cheap). when you go to install it, look around the internet for pictures to show the strategically placed zip-ties to support the wiring & hoses against vibration. I may have a few (dozen) pics too. <grin>

Off the top of my head, I would say OHR is the world's leading expert in husky wiring abrasion, fuel pump issues and general big-block weirdness.... maybe he'll chime in with some theories of what happened.

 

[268fords]

Olderhuskyriders thread on his 20,000 mile 450 is probably the best thread on this site. Great documentation throughout. I still have 17,500 miles to go to catch up with his beast. Speaking of, olderhuskyrider, does your buddy you sold it to still ride it? It would be great to hear the rest of the story of your old stallion.

 

[OlderHuskyRider]

Olderhuskyriders thread on his 20,000 mile 450 is probably the best thread on this site. Great documentation throughout. I still have 17,500 miles to go to catch up with his beast. Speaking of, olderhuskyrider, does your buddy you sold it to still ride it? It would be great to hear the rest of the story of your old stallion.

He rode it awhile and then it got stolen, he hasnt been able to recover it. I think about that bike every time I go riding.....

 

[268fords]

He rode it awhile and then it got stolen, he hasnt been able to recover it. I think about that bike every time I go riding.....

Man that sucks. Terrible ending to a great story.