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Hi,im new on here.I have looked for an answer to my problem but cant find one so hopefully someone on here can help me.I brought a zxr 400 h1 a few weeks ago,its been off the road for years and its a bit of a project bike for me.The bike wouldnt start.The fuel pump had burnt out so i got hold of another one.It appeared to work fine when starting the bike but its when the bike is running the problem happens.Smoke starts coming out of the fuel pump.I stoped the bike and removed the plastic cover on the back of the fuel pump to see whats happening.As i press the start button the pump appers to start working fine,the metal tab beats very quickly and the are slight sparks between the small plates,but when the bike starts ticking over the spark gets brighter and stronger and it starts smoking and gets very hot.If i let it carry on ticking over it will burn the pump out again which I obviously dont want to happen.Ive checked the earths on the wiring loom and they all look ok.The other electrics work ok apart from the tacho and main beam headlight.The tacho doesnt work and the headlights light up fine but when i switch to main beam they go to side lights,dont know if its all related or not but any help would be appreciated esspecialy with the fuel pump.Thanks

don't know about the fuel pump problem but the headlight main beam i would say is definitely the headlight relay gone.

Could the fuel pump relay be causing the fuel pump to burn out? I tested the resistance of the relay and cdi like it says in the electrical system in the manual and my readings were differant to what it says.Could this be my problem?

The tacho and the pump problems could be related the tacho pulse comes from the fuel pump and one of the coils

Its the coil on the right is'nt it? The clocks have been changed to mph.I have the original kph clocks and when I fit those and switch the ignition on the needle for the tacho goes to 6000rpm.Ive done that test in the manual where you disconect one of the wires from the coil and conect it to the positive on the battery,when i do this the tacho needle goes back to zero,take the coil wire off the positive battery and the needle goes back up to 6000rpm.Do you think I need a new coil?

I've replaced the coils but still have the same problem.There seems to be to many volts going to the fuel pump.I checked with a multimeter this morning.I pressed the start button once and there was around 18-20 volts going to the pump.I then poured some petrol into the carbs and got it running,with the bike running there was 50 volts going to the fuel pump.Im thinking thats way to much and probably why the old pump burnt out.Could anyone help.Should there be this many volts going to the pump? If not what might be causing it? Could it be the cdi or regulator? Any help is appreciated.

sorry, im crap with fixing leccy stuff, but can tell you its a 12 volt system .. anything approaching the voltages you are seeing is very very wrong.

lol, 50 volts is very very bad. you have serious electrical problems.

Andy4 wrote:I've replaced the coils but still have the same problem.There seems to be to many volts going to the fuel pump.I checked with a multimeter this morning.I pressed the start button once and there was around 18-20 volts going to the pump.I then poured some petrol into the carbs and got it running,with the bike running there was 50 volts going to the fuel pump.Im thinking thats way to much and probably why the old pump burnt out.Could anyone help.Should there be this many volts going to the pump? If not what might be causing it? Could it be the cdi or regulator? Any help is appreciated.

Yikes, 50 Volts
I would be chucking on a Rectifier/ regulator on there first, Then see what happens

Theres already a regulator on the bike.I've tested the resistance of it and the cdi and didnt get the readings that it says in the manual.Im not very good with electrics I just hope im testing them right because I dont want to buy another cdi and regulator if I dont need to.This could be whats causing my problems though

Andy4 wrote:Theres already a regulator on the bike.I've tested the resistance of it and the cdi and didnt get the readings that it says in the manual.Im not very good with electrics I just hope im testing them right because I dont want to buy another cdi and regulator if I dont need to.This could be whats causing my problems though

The fault will be nothing to do with your CDI, although at 50 volts it soon will be, My guess is that your rectifier/regulator has packed up and your getting 3 phaze ac volts to your pump, What is the bike charging at??? may give me a better indication, also where are you based??
Ciao
Glyn

Thanks for your help so far,I live in the forest of dean.Im not sure what the bike is charging at,how do I test that? I'll have a look on ebay for a regulator,hopefully that will sort the problem out

when the bike is running put the multimeter across the battery terminals and see what the voltage is. Should be around the 14v mark.