How to Tell If My 2006 600 GSXR Fuel Pump Is Working

The fuel pump used by Suzuki's 2006 GSX-R600 is housed within the motorcycle's fuel tank and is responsible for supplying the fuel-injection system with a steady stream of gasoline. Under normal circumstances, the fuel pump can provide several years of reliable service. However, a noticeable change in the motorcycle's performance can often be attributed to a failing fuel pump as it struggles to maintain a steady fuel output. A total failure will prevent the motorcycle from starting at all. Troubleshooting the fuel pump does require some disassembly of your GSX-R600, but may prevent an unnecessary repair.

Things You'll Need

• 4 mm Allen wrench
• 10 mm socket
• Socket wrench
• Shop towel
• Pliers
• 3 feet, clear fuel hose
• 16-gauge electrical wire
• Alligator clips
• Fuel-safe plastic measuring cup
• Fuel pump relay
• 5-gallon gas can
• Fuel pump
• Torque wrench

Instructions

1. Remove the front seat bolts, located beneath the seat cushions on both sides of the motorcycle, using a 4 mm Allen wrench. Lift the front of the seat up, then pull it towards the fuel tank until the hooks below the seat are free of the motorcycle's frame.

2. Remove the rear seat, using the seat lock built into the left side of the tail fairing. Remove the fuel tank prop rod from the tool kit in the tail fairing compartment.

3. Unscrew the mounting bolts from both frame covers, located directly below the front seat, using a 4 mm Allen wrench. Slide the frame covers toward the front of the motorcycle until they are free of the hooks built into the base of the fuel tank.

4. Unscrew the forward fuel tank mounting bolt, located between the handlebars and the front of the fuel tank, using a 10 mm socket and a socket wrench. Lift the front of the tank and support it in place, using the prop rod.

5. Unplug the fuel pump connector, located under the base of the fuel tank. Wrap a shop towel around the fuel hose, then pull the hose off the fuel pump outlet with pliers. Push a 3-foot length of clear fuel hose over the fuel pump outlet, then place the free end of the hose into a fuel-safe plastic measuring cup.

6. Connect the fuel pump's yellow and red terminal to the motorcycle's positive battery terminal, followed by the fuel pump's black and white terminal to the battery's negative terminal, using 16 gauge electrical wire and alligator clips. The fuel pump will activate immediately and begin to discharge fuel into the measuring cup. If the fuel pump does not activate, replace the fuel pump relay.

7. Disconnect the fuel pump from the battery's negative terminal. Unplug the fuel pump relay from the left side of the air box, nearest the base of the fuel tank. Install a new fuel pump relay in its place, then reconnect the fuel pump to the battery's negative terminal. Skip this step, if the fuel pump activates normally.

8. Allow the fuel pump to operate for 10 seconds. Disconnect the fuel pump from the battery, starting with the negative terminal, then the positive terminal. Measure the amount of fuel discharged by the fuel pump during its 10-second operation. Ideally, the fuel pump should have continuously discharged a minimum of 5.7 ounces in 10 seconds. The fuel pump must be replaced if the discharge was inconsistent or if the pump discharged less then 5.6 ounces of fuel.

9. Place the fuel hose in a 5-gallon gas can and reconnect the fuel pump to the battery, starting with the positive terminal, then the negative terminal, if the fuel pump is faulty. Drain the entire contents of the fuel tank into the gas tank, then disconnect the fuel pump from the battery. Pull the clear fuel hose off of the fuel pump outlet, using pliers. Skip this step, if the fuel pump is working as intended.

10. Unscrew the fuel pump bolts from the bottom of the fuel tank, using a 10 mm socket and a socket wrench. Pull the fuel pump out of the fuel tank by hand. Skip this step if the fuel pump is working as intended.

11. Apply a light coating of grease to the new fuel pump O-ring, then push the fuel pump into the fuel tank. Screw the fuel pump mounting bolts into place, using a 10 mm socket and a socket wrench. Tighten the bolts in a criss-cross pattern to 7 foot-pounds, using a torque wrench. Skip this step if the fuel pump is working as intended.

12. Push the motorcycle's fuel hose into place over the outlet. Plug the fuel pump connector into the motorcycle's wiring harness. Remove the prop rod and lower the fuel tank into place. Screw the forward fuel tank mounting bolt into place, using a 10 mm socket and a socket wrench.

13. Slide the frame covers onto the hooks built into the base of the fuel tank. Screw the frame cover mounting bolts into place, using a 4 mm Allen wrench.

14. Reinstall the rear seat onto the tail, then push the seat down until it clicks into a locked position. Slip the front seat hooks into the motorcycle's frame. Screw the front seat bolts into place, using a 4 mm Allen wrench.

Tips & Warnings

• Avoid sparks and open flames while working around your GSX-R600's fuel system. Fuel vapors can ignite, causing serious injuries and damage.

References

• "Suzuki GSX-R600 Service Manual"; Suzuki Motor Corp.; 2006
• "Haynes Motorcycle Fuel Systems Tech Book"; John Robinson; 2000