I love reading this "olde" thread!. Howdy. I’m new to THIS forum, so please be kind to an old Phart.
I am the original owner of my 2003 40th Anniversary ‘Busa, and it’s been a "dealer’s bike" since new. I’ve never had an issue with it, before now. The bike is "bone stock", except for a K&N air filter and Leo Vince exhaust. After it sat for well over a year, (family stuff — don’t ask), it now won’t start. It had Stabil in the fuel. The fuel pump wasn’t kicking on (at first; it runs now), so I checked the fuse, fuel pump relay, tip-over sensor, etc., and AOK. gotta have something wrong with/ the fuel pump, right? So it’s into the tank we go. YUCK! Everything in there was olive drab in color. After pulling the pump out, I hooked it directly to 12V and (after a coupla ON/OFF cycles, the pump started to run. Good (I thought). NOPE. The bike still wouldn’t start, using . Fuel filter clogged? Let’s check. Took the pump apart and swapped out the filter on the pump intake. All parts (now clean with new gas), tried it again. NOPE! OK, let’s check out the fuel pressure. It produced about 60psi while the pump was running but fell off to zero within a second after it stopped. Hmmm… pressure regulator stuck open? OK, took it all apart again and tested the regulator w/ compressed air @ 60psi. The bypass (high pressure condition) worked fine. When the air-tank pressure got below 45psi, the bypass closed (as it should) and it held the air pressure. Thinking that maybe the air had blown all of the olive drab crappola out of the regulator, and unstuck it, I put it all back together and tried again. NOPE! drat… In an obscure part of the service manual it mentioned a "fuel pump check valve"; there is no indication I can find of where it is! Must be internal to the pump assembly, but where? Any ideas of how I can check this out?
I’m kinda glad I’m not paying a dealer for all of my labor on this.