Yamaha VIrago XV5535 Bobber Project, Part 1 Testing The Fuel Pump!

In this video I begin the initial tests preceding the maintenance work that will be required by testing the flow rate of the electric fuel pump.
For those unfamiliar with external electric pumps on bikes and cars, these typically use a make / break contact points type assembly to pulse a rubber diaphragm which is inside the non serviceable sealed pump body.
This diaphragm alternately sucks in and expels fuel and using two hose fittings and appropriately set one way valve on each, sucks fuel from the fuel tank and pushes it into the carburettor.

[@mikehunt-zx8tr]

I just bought a 98 virago 535 as my first bike and this is pure gold to me. I'm getting a really good understanding of how the fuel system works and I'm excited to watch the rest of this series to learn more. I like to think I'm pretty mechanically inclined but this is exactly what I needed to feel more comfortable with the idea of working on my virago incase something goes wrong. If your reading this thank you very much.

[@spidiq8]

dawn s You're welcome, glad you're finding it useful and I hour you enjoy your bike.

[@humanentity2214]

Very detailed video. Thanks! I recently replaced the fuel pump and added a new plastic, transparent fuel filter on my virago. For some reason, the inlet of the fuel pump keeps leaking even when bike is off.

[@spidiq8]

Do you mean where the fuel pipe connects to the filter?

[@joeyong1418]

The fuel pump is pressure activated, so it should pump fuel until you block the outlet pipe by pressing your thumb over the pipe opening.Does not seem to be working at all.Cranking does not activate the pump if the pipe is already disconnected.

[@spidiq8]

Good to know thanks.

[@Red19UK]

interesting stuff, cheers for uploading

[@spidiq8]

Thanks, hope it's useful.

[@theclassicsaabguy236]

Hi ! Did a new fuel pump solve it ? I have the exact issue ! Thanks

[@spidiq8]

It didn't, there was something amiss with the wiring and wiring is out of my ball park, i'm rubbish with electrics.

[@Blash1]

When i turn the key the pump sometimes doesn’t make any sound or it has a delay and seems to inject very little amount of fuel, could this be a fuel pump problem or something electrical?

[@spidiq8]

I'm not entirely sure, electrics are not something i'm great with.

[@AxelAndersen]

Nice video. I have question regaring the "dummy" tank. I bought a Virago 535 from 87, with a "real" tank on the top. However, when i fill it nothing comes out of the bottom hole. I have checked that I can blow air inside with compressed air. I also see a hose inside the tank when using a cam on a wire. Any ideas?

[@spidiq8]

Does it have all the hoses and such to the frame tank? I'm unsure why the fuel wouldn't flow straight through.

[@AxelAndersen]

@@spidiq8 I have unmounted the tank, so its just sitting on my desk, filled with fluid and not a drop coming out

[@spidiq8]

@@AxelAndersen but you say you can blow into it? Have you tried suction? Obviously not direct to the pipe but if you could rig up something. There shouldn't be any vacuum related innards but that's a thought. If nothing on either then the pipe must vent through the tank but exit elsewhere. If you cap the tank and rotate it over a large container and the pipe does vent inside at some point during rotation fuel should exit.

[@AxelAndersen]

@@spidiq8 I dont see any exit any where exept the bottom hole and the fuel cap. Could the gasoline nozzle be connected to the pipe inside the tank?

[@spidiq8]

@@AxelAndersen I really couldn't say without seeing it. It's baffling. If there's a hole to put fuel in there has to be a hole for it to come out and if it's not something is blocking it or it's been altered for some reason. The connection hoses are wide bore because it literally has to drop through to the lower tank so unless someone took a later model tank and sealed it to fit to an earlier model bike with the filler under the seat I'm stumped

[@carhard_oldmachine2743]

Good afternoon! Who can tell me, I can’t solve the problem, the yamahs virago 535 stopped pumping gasoline, the fuel pump is crackling and doesn’t pump, I bought a new one, the same thing is cracking and doesn’t pump, I took this new pump, I thought it was also broken, but no, I just inserted the hose into a bottle with gasoline from there shakes the beggars. I removed all the hoses from these two tanks, the one that blows from the bottom is all blown through these two hoses that are connected to the tank above. but the only fitting from where gasoline should go to the fuel pump, blow there, don’t blow, or suck back, no reaction. Is it supposed to be like this? Could there be some kind of valve inside this lower tank or something clogged?

[@DaveSkillzGaming]

thats one way to burn out your starter lol

[@MarstonBoii]

Hey man! Amazing video! I've checked each of them, great learning content. I wanted to ask you a question, hope it is not too silly. I do own virago 535 1988, which has dummy tank. Would Virago 95+ tank fit? I really want to replace dummy.

[@spidiq8]

I've never tried to swap one for an earlier dummy plastic tank but theoretically it should. I don't think there are any changes to the frame that would affect it. The one thing that will be tricky is that you'll need to also change the under seat tank for the later one with the feed pipes from the top tank. Depending on how much bother you want to go to I can say it doesn't add that much more fuel. You're still looking for a filling station every 100 miles. Had I kept my own I would have fitted something like a Mustang or peanut style tank.

[@karlh4313]

Hey 👋 got another question for you.. why would the pilot screws have to be turned almost all the way in instead of 2&1/2 turns out to get a good air/fuel mixture? What would be causing that? Thanks

[@spidiq8]

Sounds like either a blockage or dirt in the carb or an air leak.

[@karlh4313]

@@spidiq8 thanks split o-ring

[@1menwolfpack550]

When opening switch the pump should make a clicking sound Right

[@spidiq8]

Generally they do but it depends if the float bowls are already pressurised I think, i'm no great with electrics.

[@sisaketmike]

It's insane to use so much cranking, it messes up your starter. And there's no need to crank the engine, the pump delivers until the carb bowls are full and the valves close. Then it stops. That's why you usually hear a few clicks when you switch the ignition on.

[@spidiq8]

Thanks for the info

[@firebird14420]

Do you stick with Yamaha brand feul pump or what did you go with??

[@spidiq8]

I don't know, it was supplied along with the bike.

[@garyconstant4234]

Can the actual pump get clogged up with crud

[@spidiq8]

Absolutely. Especially if a fuel filter isn't fitted and there's debris in the tank.

[@garyconstant4234]

@@spidiq8 yeah it’s got a fuel filter and it’s nice and clean but the bike was sitting around a bit before I bought it so that’s what’s making me think it could have a dirty fuel pump ⛽️ hope you’re keeping well as we’ve spoken before about your lovely cat gizmo 👍

[@spidiq8]

@@garyconstant4234 It's possible but the first thing I'd do is get some fresh fuel in it. The modern stuff goes off quicker than milk. I'm not bad thanks. Just too busy lately. I need more KZbin video creating time. Hope you're well yourself.

[@frankpadilla3741]

I have seen a whole lot of subject about the fiel filter fuel pump fuel line etc. But none of them actually show where the fuel filter is for a 1991 virago 1100

[@spidiq8]

That model is slightly different to the 535 so I could tell you if the fuel pump is in the same place, easiest way to find it is to trace the fuel line from the carburettor back until you locate it, they're typically under a panel or the seat area to keep them out of the weather and away from engine heat.

[@frankpadilla3741]

@@spidiq8 i appreciate that thank u found it

[@stevegoulet5499]

I have a 1994 yamaha virago xv535, I recently have deleted the fuel pump because the fuel tank under the seat was very rotted and could not be reused. I went with a cafe style tank and the bike is now gravity fed to the carburetors. The bike now seems like it is struggling to run at higher rpms. I tried bigger jets because it has pipes with very little baffling. Do these bikes need pressure from a fuel pump or can they run from a regular gas tank? Any advice would be greatly appreciated!

[@spidiq8]

If the fuel is above the carburettors gravity feed should be adequate. Is the tank split high on the underside and is the fuel tap on one side only? If you have a vacuum feed fuel tap have you tried it on the Prime position bypassing the vacuum. Other possibilities are that you may need a high flow fuel tap. Pingel used to be popular and available in a wide range of tank fitments. Having said all the above, it may be that a small amount of additional pressure is required to fill the float bowls on these carbs as they're an unusual side on layout.

[@stevegoulet5499]

It has fuel taps on both sides and yes the inner middle wall of the tank is tall. The fuel taps seem free flowing I also have a clear piece of tubing right before the carberators so I know there is fuel in there. I think I'm going to try rigging up a fuel pump as I have a new one for this bike. Thank you very much for your fast response and information!

[@spidiq8]

@@stevegoulet5499 No problem, taps both sides obviously removes the possibility of starvation due to fuel pooling in one side. Also with 2 taps, provided your cap is venting adequately flow should be sufficient. Try a high rev run with the cap popped open just to rule that out, I've had blocked vent holes before causing a vacuum in the tank. If not then a pump, (the original will be more than adequate) should ensure sufficient feed. Are you using the stock airbox setup?

[@stevegoulet5499]

Yes i will try that just to make sure thank you, and the air filter is just a stock replacement and was not altered

[@AA-69]

PUT IT BACK TOGETHER.... PROPERLY !!!!

[@MrRagAndBoneMan1]

hiya ,,, great vids... been great for me being a novice to all this.. don't s'pose you got any vids on HT leads.. it appears my Virago is only firing on 1 cylinder... forward cylinder is Hot.. rear Cold.... i've checked for a spark,, but no joy.. any advice would be great..

[@spidiq8]

Thanks for the feedback and glad you've found them useful so far. I don't have any specifically on HT circuits, I don't remember if these are separate coils as it's an age since I owned my own and worked on this. If separate try swapping them and see if the cylinders swap, if so, check the LT (low tension), thin wires feeding to the coils with a multimeter, if they're getting voltage then it has to be the coil, lead or plug cap. I'll try to see if I've still got my manual and have a look there.

[@memybikeni9931]

First I thing I would do is swap the coils over, as they are integrated with the HT leads. If you get forward not firing and rear is, you’ve found the issue. If not work back from there to the ignition. May be a leaky lead, if you get a shock off the one not firing.

[@AA-69]

IGNORE THIS GUY, HE'S A PRAT WHO KNOWS NOTHING.

[@memybikeni9931]

Pump sounds a little Ill