Intermittant fault... Engine dies like it runs out of fuel.

[sc0tt]

Crap doesn't generally swirl around, the pick up is at the bottom and will just pull through to the fuel filter.

[moanthebairns]

if this works you will never hear the end of it.

[sc0tt]

moanthebairns said:

if this works you will never hear the end of it.

I'm sure.

[sc0tt]

PP, What do you need to do to get it going after it has died?

[moanthebairns]

sc0tt said:

moanthebairns said:

if this works you will never hear the end of it.

I'm sure.

To be fair it's just about the only thing he has over looked.

The sporadic nature of it makes it seem plausible

Always best to start up line and work your way down I find.

[Andy XRV]

I had the same problem on my Fireblade and it was the in tank filter, part number 12 below. Assuming it's not broken up it is cleanable.

[grahamr88]

Does your fuel tap have a vacuum pipe running to it, so it only opens when the engine is running? If so, take it apart and check the rubber diaphragm, you might find it's got a small split in it.

[MotorsportTom]

Nothing useful to add in the way of what it may be but if you use the following website it should have all the exploded diagrams so you'll be able to see if it has what kind of filters where etc.

CMSNL.com

They have Suzuki, Kawasaki, Honda and Yamaha so good for most!

[Prof Prolapse]

Biker's Nemesis said:

Have you just fitted a new fuel cap.

Yes. But it's done it with this and another two including the OEM one.

I asked the garage to check this and they rang me earlier to say it sealed correctly and wasn't the cause.

[Prof Prolapse]

Andy XRV said:

I had the same problem on my Fireblade and it was the in tank filter, part number 12 below. Assuming it's not broken up it is cleanable.

I didn't realise I had one. I've just been through the honda manual again and still can't find any reference to it.

If the tank is drained and the fuel tap removed it should be easy to find and clean.

[Prof Prolapse]

Biker's Nemesis said:

I would start by checking all pipes, maybe one of them has a kink or one has lost its rigidity and is compressing flat when the tank is in place.

It will be something piss simple, can you hold the tank away from the bike while it is running?

I will do but I'm not sure its that.

I've checked them twice and just refitted them all the other day after doing the clearances. I even checked up all the carb hoses for splits or even the start of them. That was another thing I asked the mechanic to double check.

The biggest ball ache is because it's intermittant. The garage couldn't reproduce the fault, and historically I have done things (like get a new fuel cap) and just have to wait for 4 months before it packs in again.

[Prof Prolapse]

MotorsportTom said:

Nothing useful to add in the way of what it may be but if you use the following website it should have all the exploded diagrams so you'll be able to see if it has what kind of filters where etc.

CMSNL.com

They have Suzuki, Kawasaki, Honda and Yamaha so good for most!

That is incredibly useful. I really could have done with this when I was taking it apart for the valve clearances!

Also shows very clearly I have a filter in the tank. So I'll get that apart.

[Prof Prolapse]

sc0tt said:

PP, What do you need to do to get it going after it has died?

Nothing that I'm aware of. Stuck it in neutral and it kicked over fine.

To be honest mate I don't remember. It's literally a few times over years, it's difficult to recall. It could even be different things given how much has changed on the bike in that time.

[Yarders91]

Is your bike carb'ed? Could be carb icing. My bandit 600 suffered from it quiet badly in the winter months. A touch of Isopropyl alcohol into a full fuel tank fixed it for me.

All the symptoms you describe is what mine did too

[Yazza54]

Hooli said:

Sounds possible, I used to drive a coach that did the same when a rubber glove dropped in the tank covered the pick up.

Hooli at 4mins

http://youtu.be/hFzztGhAn34

[DrDoofenshmirtz]

Fuel pump pressure switch
The fuel pump has a pressure switch mounted at the back of the fuel pump motor. The way it works...when you turn on the bike the fuel pump spins and fills the carbs - once a certain back pressure is reached in the fuel line, a little plunger switches the motor off. As the fuel is used up, pressure drops and the plunger switches the motor on again...rinse/repeat.
It'll be the contacts inside the fuel pump motor housing. They'll just need cleaning with emery paper.
A complete replacement part is available: http://www.ebay.co.uk/itm/Fuel-Pump-Petrol-Pump-Re...

Cleaver little bit of design.

[Hooli]

Yazza54 said:

Hooli said:

Sounds possible, I used to drive a coach that did the same when a rubber glove dropped in the tank covered the pick up.

Hooli at 4mins

http://youtu.be/hFzztGhAn34

Close, but bigger coaches & it tended to be school trips who were noisy enough on their own.

[Benni]

OP, when the engine dies, did you ever open the fuel tank and listend to air being sucked in ?

Could that problem be caused by a blocked breathing hole in the filler cap

which could lead to vacuum builiding up in the tank ?

[krarkol]

As others have said, if it happens again open the tank and listen for air rushing in. Could be as simple as a blocked breather.

On my bandit 600, I had a bad terminal and when at high revs the vibrations made it continually connect and disconnect so the bike would splutter and backfire with a good flameshow. Check all your wiring as it could just be a dodgy connection that comes loose occasionally.

[Andy XRV]

Prof Prolapse said:

Andy XRV said:

I had the same problem on my Fireblade and it was the in tank filter, part number 12 below. Assuming it's not broken up it is cleanable.

I didn't realise I had one. I've just been through the honda manual again and still can't find any reference to it.

If the tank is drained and the fuel tap removed it should be easy to find and clean.

I wasn't sure either but when I searched your bike I found that diagram. As you say, you've only got to remove the tap to check it. My bikes only a year older than your and I was very surprised by the amount of rust in the tank.