Zane Formula 750S Fuel Pump/Electrical ?s

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wallycycle

New member
Location
SoCal
Zane Formula 750S. Problem: No start/run. bike just quit running while I was riding it.

Motor cranks and have spark. suspect no fuel. When I turn the ignition key on, don't hear the pump prime for a second or so. (I assume I should be hearing that?)

Pulled the cap on the fuel pump relay and it actuates when the starter switch is pushed. When I pull apart the connector that feeds the fuel pump and put my voltmeter on the female contact, I don't have 12V when the starter switch is pushed so suspect that the pump is not getting power.

Questions:

Is there a separate fuel pump fuse and if so where? My shop manual doesn't show one.

Side stand switch:  Does this have any connection/impact to spark or fuel pump? When I move the side stand up and down, I get the red light in the instrument panel so the switch seems to be working? Does it do anything else besides letting me know the side stand is down?

What is the 40A fuse for with the red cap on the left side by the battery? After pulling it I can still crank the bike, lights work etc...

What I have not done and am thinking of doing next to eliminate a bad fuel pump is to attach 12V directly to the feed cable for the fuel pump that is on top of the tank to the right of the fuel level lead and see if I can hear the pump running. Any thoughts on if this is a good idea or if I can ruin something?

Any comments are much appreciated.

Thank you.






 
Yes you should hear the pump prime

No separate fuse for the pump only the relay, 40 amp is the regulator fuse

Side stand switch control does indeed control fuel or spark , I dunno which one but that may well be your trouble, Im gathering you haven't don the sidestand bypass mod, id be doing that as a matter of urgency even if that is not the fault, I wouldn't be trusting that the light on the dash means the switch is working, they are  known fault and should be bypassed, Marty on here has bypass switches  or you can loop wire 1 and 3 which is all the switch does, im tryng to find a picture of it , I have one somewhere 

Have you tested the relay to make sure its working? has the bike been sitting for a while? they really dislike not being used, the fuel gums them up

Sounds more electrical from what you describe and a sudden stop would lead me to the sidestand switch first
 
Hello Cosi,

Thank you for your reply. I checked the actual fuel pump relay (#10 on schematic) and it's okay. I also swapped out #11 and #12 relays (radiator fan and lights) and still no fuel pump prime when I turn on the ignition. I don't get 12V at the fuel pump connector when pressing the start switch or just turning on the ignition. So I'm suspecting something/switch is blocking power to the pump. I am considering either getting a Side Stand Relay Bypass Kit which I assume replaces the 6 Pin Relay (#14) next to the fuse box to see if that's the issue. Or just replacing that OEM relay (part #01900100087). I contacted Alto Racing and they no longer have the kit or Laverda spares. 3cmoto has the OEM part. I'm waiting to hear from OCT and Wolfgang to see if they have the OEM part or the bypass kit.

Additionally, my schematic of the Fuel Injection System show a "Fuel Pump Safety Switch (mercury switch)" inline to the power supply for the fuel pump. Can't find that part in my parts manual nor on the bike. Do you know if this switch is integral to something else (#14 above or ECU)?

Thank you again for your help.
 
I have the sidestand bypass units as well as the OEM sidestand unit available but I am out of town until the middle of next week.  Most people seem to be getting just the bypass unit but if you are wanting to maintain the bike as OEM then you could get the original unit and just tuck it away.


I know you said the light inside the tach is working to show whether the sidestand is up but you may want to put the rear of the bike up on stand and take a look at the push relay for the sidestand bypass.  Its located behind the sidestand (kind of hard to get to) but with the sidstand up you can take a look and see if its screwed in securly.  Also it can get gunked up and not release and if it doesnt then the bypass will think the sidstand is down and the fuel pump wont fire.  Also, you may want to make sure its still completely plugged into the harness.  It runs up the side of the bike kind of behind the frame on the riders left side and plugs into the harness with a small plug.  If the light is working it should be okay but just something else to check.

My experience with the fuel pump has been that they can sometimes quit if they are run when the tank is completely dry.  Also if they are original they can fail if someone put something like Stabil into the gas tank and it sat for a while and gummed up the tank.

I wouldnt recommend trying to attach the 12v to the leads on the pump directly but you may want to run a OHM test on the two wires that feed to fuel pump (under the main seat).  I have seen instances where the black plugs that clip on the fuel pump can come off.  Unfortunately these plugs cant be accessed without getting the fuel pump out.

NOTE:  Its kind of a pain to take the pump out (takes about 4 hours to replace) but can be done by a reasonable competent home mechanic.  Major problem is you have to remove the black airbox assembly, disconnect the exhausts and underseat plastics and the loosen the rear subframe.  But this may end up be a blessing in disguise because it gives you reason to go into the tank and replace the fuel line hoses and filter (which I also have in stock).  The fuel lines can degrade over time due to their constant insertion in liquid so replacing them is a good idea, also the fuel filter inside the tank is probably due for a replacement.

Feel free to shoot me an email directly at dallaslavowner@gmail dot com and I will work with you to get your zane up and running.
I have detailed instructions on how to replace the fuel if necessary and can also direct you to replacement fuel pump sources.
 
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