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2003 Cali Stopped, won't go again

M

Mr Revhead

Tuned and Synch'ed
Joined
Oct 19, 2015
Messages
29
Location
New Zealand
Hi, I'm in need of some help
I have a 2003 Cali EV
It stopped today, was in 1st gear slowly approaching stopped traffic. It went out like It have been turned off.
Will crank but not fire.
Can hear fuel pump when key turned on
All fuses checked and swapped some around to check
Relays click with power etc swapped positions to see if that helped, nope.
Oil pressure light does NOT light up when key turned on? But can short the sender and light comes on
Only the neutral light come son with key

Any hints or anyone had this before?
 
The faulty oil pressure sensor will not prevent the bike from starting. Can you check to see if the plugs are sparking? Do you have access to diagnostic software? Does you Cali have the external or internal fuel pump? If you still have the electric fuel petcock for the external fuel pump that may have failed. Still questions to be answered.
 
There is spark
I mention the oil light as that happened at the same time. Possible fluke coincidence though.

Internal fuel pump. I'm in the middle of pulling the tank to check the internal hose
 
Good luck with that assembly, it is a real bugger to get in and out without causing damage to the fuel level sender. I'd love to get my hands on the engineer that designed that tank hole and pump plate. A bit larger hole and it wouldn't be an issue. The internal pump California's have the same half plastic filters that caused trouble in the CARC bikes. The BMW fuel filter for K bikes and oil heads is an exact replacement. Check the CARC section for more information on a replacement filter. If it has lasted 13 years, that is pretty good.
 
Seems to be plenty of fuel in the line out of the tank, quite a bit dribbled out of the pump.
External fuel line was kinked and a little frayed as well.

But the interesting thing I just found, a tiny sewing needle feed into one of the injector wires.... I wonder if it was left over from a previous issue. Will ring the previous owner
 
If it has the internal fuel pump, don't rule out either the filter has come apart or the fuel line popped off due to ethanol. Well documented. There would still be plenty of fuel in the external line as the pressure to feed the injectors comes from the pump. The easy test has been to open the cap, and turn the ignition on... If you see fuel swirling, there's an issue.
 
The pump primes as normal, runs for a couple of seconds and stops. It doesn't run continuously like it would if the fuel line had come off.

I'm becoming more convinced it's something thats stopped the injectors firing
 
Could be, or it could be a cracked and failing fuel filter. Check that along with finding out what the P.O. did to the injector wires.
 
Seeing as the tank is off. I'll have a look at the insides then.

I made an error there, it wasn't an injector. It was the TPS and it was for setting it up.
 
Mr Revhead said:
Seeing as the tank is off. I'll have a look at the insides then.
I made an error there, it wasn't an injector. It was the TPS and it was for setting it up.
Click to expand...
I would, and does your EV have a lambda/02-sensor?
 
Well F*** me.
That is a mongrel to get out of the tank!!


Especially when that hose HAS popped off and gets in the way.
So, even if your pump sounds normal, it can still have that line popped off!

Problem solved. Or will be when I get a new piece of hose and clamps.

Btw the filter is a metal one in there, been done before I think
 
Be sure to get submersible fuel line as well as FI or oetiker clamps that don't cut into the line.
 
Yep will be the proper stuff.
I'll probably use Mikalor clamps. It has Oetiker type clamps on there now and that's what popped off, plus another was loose enough I just pulled it off by hand.
 
Mr Revhead said:
Yep will be the proper stuff.
I'll probably use Mikalor clamps. It has Oetiker type clamps on there now and that's what popped off, plus another was loose enough I just pulled it off by hand.
Click to expand...


It isn't so much that the oetiker clamps get loose, but that the hose deteriorates.
 
Quick update, it's running again. I didn't replace the hose, it's been already been replaced with fancy PU stuff before and was fine.
It was the clip that lost tension and let go. Or possibly it wasn't tensioned properly when replaced. So I replaced all clips with proper Mikalor stainless fuel line clamps.
 
I believe the hose and clips were original, Warwick. I never replaced them, as I thought the bike was outside the "bad batch" period when this problem surfaced. Never touched the filter either, so the metal one was original too.

However, had I been in there, I would have replaced the hose on principle, since it has been sitting in fuel for 15 odd years. It's the getting in there that's the hard part.
 
Ok, well the hose is definitely ok. No signs of swelling, hardening or perishing and is a clear polyurethane hose. I'm confident it's fine. Guess I'll find out if it's not! As far as access goes, it wasn't too bad... Not a fun job but certainly not the worst I've done.

The main issue I have is sourcing a suitable replacement. The local hose supplier here has nothing suitable. None of their PU hose is flexible enough to fit. There is another supplier I can try, which I might do and redo it on a rainy day. But for now, it's running again :D
 
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