[RedZ1K]

I was asked to have a look at a guy's Z500 today, he can't get it started.  I immediately noticed that the fuel pump isn't running when the key is turned on.  All fuses are good and the engine will crank no problem.  I'm trying to get at the relays now but they are tucked up above the glovebox and I can't figure out how to get to them.  Can the glovebox be removed to gain access?  On my 1000 they are right in the center behind the storage box but these ones are well hidden.  Is there any other reason why the pump wouldn't run, besides maybe the pump itself?  The machine is only a couple years old with ~1600km on it.  He is willing to take it to the dealer to look at but he's only in town for a few days over xmas and wanted to have some fun with it.  Otherwise it won't get looked at until spring/summer.  Thought I could try to help him out and told him I'd look into it.  Thanks!

[NMKawierider]

I was asked to have a look at a guy's Z500 today, he can't get it started.  I immediately noticed that the fuel pump isn't running when the key is turned on.  All fuses are good and the engine will crank no problem.  I'm trying to get at the relays now but they are tucked up above the glovebox and I can't figure out how to get to them.  Can the glovebox be removed to gain access?  On my 1000 they are right in the center behind the storage box but these ones are well hidden.  Is there any other reason why the pump wouldn't run, besides maybe the pump itself?  The machine is only a couple years old with ~1600km on it.  He is willing to take it to the dealer to look at but he's only in town for a few days over xmas and wanted to have some fun with it.  Otherwise it won't get looked at until spring/summer.  Thought I could try to help him out and told him I'd look into it.  Thanks!

I agree, they suck to get to. The 800s are the same. The box does come out but it isn't easy as others have said. Two screws on the firewall and too others on the dash as I recall. You can pull the hood storage tray and get to the end relays.

I know it cranks but..the kill switch kills the three systems-starter, ignition and fuel. It like the rest are not water proof..only resistant. One or two contact in it can be corroded where one or two won't be leaving some systems to work and others not to. After using contact cleaner and working it on and off a few times it that is the problem it may start working again. Otherwise check all the connections...see if power is in fact getting to the pump. If so..the pump is probably locked. If it was outside it may have water that froze.. May also pull the line and see if it already had pressure.

[doug80638]

You didn't mention if there were any MIL light flashing out codes. Any other indicators?

It seems that faulty connections are common to these types of failures. This forum recently reported those same symptoms and it turned out to be  that a voltage line to the ECU had broken.

http://cfmoto-forum.com/uforce-800/2015-u-force-that-wont-start/msg31880/#msg31880

Others have found faulty connections at the fuse holder and connectors that had become disconnected.

Trace the line back from the pump until you find voltage.