I need a fuel pump relay - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

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SV650 Gen2 (03-15) Tech Info, advice or questions specific to the 2003-2015 model SV650.

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Old 09-11-2019, 08:03 AM   #1
Jay Bless
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I need a fuel pump relay

I'm looking for a fuel pump relay for 05 sv650 in Louisville, Ky
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Old 09-11-2019, 08:06 AM   #2
Jay Bless
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Will an 07 work on my 05
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Old 09-11-2019, 09:19 AM   #3
MotoTrackSide
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Re: I need a fuel pump relay

yes. whats exactly is happening to the pump?
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Old 09-11-2019, 09:32 AM   #4
Jay Bless
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I get a 1 second prime and nothing else when I turn killswitch on it's the only thing that was "tampered with"
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Old 09-11-2019, 09:32 AM   #5
Jay Bless
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Also discovered it's an SV650K5
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Old 09-11-2019, 09:52 AM   #6
Jay Bless
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Went ahead and ordered the part. Hope that's the issue and then I can focus on getting the wiring cleaned up
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Old 09-11-2019, 11:47 AM   #7
MotoTrackSide
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Re: I need a fuel pump relay

I went through a few trial and errors troubleshooting my fuel pump. I am on my 3rd one which is from a k8 and k6 throttle bodies. I will find out this Saturday if it's a go on circuit.
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Old 09-11-2019, 11:57 AM   #8
TeeRiver
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Re: I need a fuel pump relay

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Originally Posted by Jay Bless View Post
Went ahead and ordered the part. Hope that's the issue and then I can focus on getting the wiring cleaned up
My apologies, Jay. My poorly worded reply in the other thread (now edited) makes it sound like I am saying the fuel pump relay is bad. Most likely the relay itself is okay. What I meant to say is the hacked wires to the relay are the likely problem, not the relay.

Where did you order the part from? Please try to cancel, send me a PM, I will reimburse you for any money lost.

Good first step to find the problem is remove the tape from the hacked wires and inspect the connections. Disconnect the battery when exposing the wires as the Red/White wire has constant power even with the key "Off". There is a good chance a flaky connection on one or more of the hacked wires is causing the C41 problem.

If still seeing C41 after inspecting/fixing the fuel pump relay wires then a few electrical tests can be done to isolate further.
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Old 09-13-2019, 06:55 AM   #9
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What would be the easiest way to remove the wiring from the connector so I can fix it right without an entirely new harness
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Old 09-13-2019, 10:30 PM   #10
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Re: I need a fuel pump relay

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Originally Posted by Jay Bless View Post
What would be the easiest way to remove the wiring from the connector so I can fix it right without an entirely new harness
You have a few options:
1. Solder then cover with heat-shrink. Here is a good how-to video. You will need proper tools, some experience would be good.

2. Use Wirefy Solder Seal Butt Connectors. Only need a heat gun to use but given how close the four wires are it would be difficult to properly apply heat (need to rotate the wire to get to all sides) and might do damage to adjacent parts given the tight space.

3. Butt crimp connectors. These are generally a bad idea, especially if using the cheap autoparts store kits. Crimps are excellent if done properly (all the SV650 harness connections are crimped) but it is easy to get wrong. Only do crimps if you have a professional ratcheting crimp tool with wide-crimp dies, high quality matching crimp parts and prior experience.

4. Replace the harness. It is labor intensive but something you can do yourself without special skill. $50 for a used harness on eBay, guaranteed good connections. I know you said you do not want to do it but this might be your best bet.

5. Have a reputable shop do the repair.

Keep in mind several things can cause an SV650 C41 error. Based on the looks of the existing repair there is a good chance the problem is there but no guarantee.

Have you taken the tape off the wires? How does the repair look underneath? Best to understand what you currently have before going further.

Good luck.
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