Bike Wont Start - Confirm on Suspicion?

Hello! I just bought a 2010 FE450 and it had a lot of problems. The previous owner didn't take care of it and I figured I could handle it. He installed a dual sport kit incorrectly so I rewired the entire bike to incorporate the dual sport kit with the existing harness. So I finished all that and went to start it and nothing. The starter motor cranks but it wont start. When I bought it the bike would start right up. I don't know what's changed, I haven't touched the engine at all. When I press the starter button sometimes i'll hear the pump go and after that usually a bit of back fire but it wont start. Most of the time however I don't get any fuel pump, just start motor. I got it to start up once and it ran for a minute or two then died. Pressed the button again and it started right up only to die a few seconds later. When it was running I was able to read a code about the air temp? Not sure. Does it need a new pump? What can I test?

I've been all around this forum and the internet and I cannot for the life of me figure it out. I just want to make sure I'm not buying a fuel pump that I don't need.

Thanks in advance for your expertise!

Rainerio said:

Don't have a clue. But not bad thing to have even if it's not the problem (fuel pump) some day you may need it. Pump, clean fuel injector see how it sprays first, check/replace fuel filters two That I know of. Fuel regulator. Maybe if not hard disconnect that kit if it runs start reinstalling one wire at time till the problem comes back. Good luck

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Thanks for the reply! So I took the pump out and when I apply voltage the pump runs fine. I pumped gas through it and when it came out of the pump it came out black/dark gray. Possibly the fuel line is disintegrating so I'm going to replace that and clean the injector but that still doesn't explain why the pump only runs sometimes. The filters look good...

LadyBerg said:

So I take it that you have taken out the fuel pump assembly from inside the tank? If you took out the fuel pump you would see the condition of the fuel line so that's why I ask. If it ran before you installed the dual sport wiring kit something involved with that could be the problem. Whose DS kit did you install?

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Well I took out the assembly but it's still connected to the original line, the line that exits the tank. I put the pump inside a bucket of clean gas and when it came out the other side of the tank (the side that goes to the engine, next to the fuel pump plug) it came out this blackish/dark gray color.

Edit: It was a Tusk dual sport kit.

Okay. So the fuel pump is working. I've replaced the fuel lines. I've confirmed the injector is working. The pump is getting power. I don't understand...

It could very well be a wiring issue because when I press the start button I SOMETIMES hear the pump. Very rarely. And when I do the FI light goes on for a second then goes off. However most of the time the FI light just flickers when I press the starter and I don't hear the fuel pump. Any ideas?

jon andersson said:

It worked before you fixed the dual sport kit? Go through what you did and see if you can find a mistake.

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All I did to the dual sport kit was remove the direct connections to the battery, cut out the original switch thing that's stock on the husabergs then wired the proper wires to the original plug. Then Just plugged it in. I have checked my wiring multiple times I have no idea why it's doing this. I think it could be a bad ground wire but I already found one bad ground wire and fixed it... Not sure where else it could be. This is so frustrating! :furious:

Thanks for your comment, I'll try to go through the wiring again.

UPDATE! The bike STARTED! So turns out the there was indeed a bad ground wire! All the ground wires in the front of the bike are not properly grounded. Even though I ran my own wire they still aren't grounded! Will update again when I have a fix. I'll get some pictures too. Maybe it will help someone!