Replacing Fuel Pump In Triumph 955I: Step-By-Step Guide

The Triumph Daytona 955i is a motorcycle that was manufactured between 1997 and 2006. The fuel pump is located inside the fuel tank and can be accessed by removing the seats, battery, and side plastics. The fuel pump is powered by the bike's electrical system and is controlled by the Engine Control Unit (ECU). Issues with the fuel pump can include a lack of power, a faulty ground connection, or a malfunctioning ECU. When troubleshooting, it is important to check voltage readings, ground connections, and error codes. Replacing the fuel pump or ECU may be necessary if issues persist.

Disconnecting the fuel pump

Before beginning, it is important to ensure you are wearing appropriate safety gear, including gloves and eye protection, and that you have a suitable workspace with a flat, level surface to park your motorcycle. It is also recommended to run the fuel tank as low as possible before starting to reduce the risk of spillage.

First, remove the seats and the battery, disconnecting the negative terminal first for safety. Next, locate and remove the battery holding box bolt at the bottom and the two bolts attaching the rear of the tank. Loosen the rear tank bolt, then the front bolt using a long Allen wrench to avoid scratching the tank or bars.

Now, remove all the side plastics and the turn signal holding plastics. It is also helpful to remove the black and green plastic frame covers on the right side, as there is a connector to the fuel sensor/sending unit that can be easily missed. Disconnecting this connector is crucial, as forgetting to do so can make removing the tank frustrating. The fuel line is a very tricky little clip that is easy to remove; simply squeeze and pull down.

At this point, you are ready to lift the tank. It is advisable to have help with this step if the tank is still relatively full, as it will be heavy. Lift the back section of the tank up to the level of the frame, then pull back and up. With the tank removed, you can now access the fuel pump for further maintenance or replacement.

It is important to note that reassembly is the reverse of the disassembly process, and it is crucial to ensure that all connections are secure before starting the motorcycle.

Removing the tank

First, remove the seats. Then, remove the battery, starting with the negative terminal, and the battery holding box bolt at the bottom. Next, remove the two bolts that attach to the rear of the tank and loosen the rear tank bolt. Now, remove the front bolt—a long Allen wrench will be helpful here to prevent scratching the tank or bars.

At this point, you will need to remove all the side plastics and the turn signal holding plastics. It is also helpful to remove both the black and green plastic frame covers on the right side as the connector to the fuel sensor/sending unit is located here.

Now, disconnect the fuel pump and fuel line connections. The fuel line is a very tricky little clip that is easy to remove—simply squeeze and pull down.

You are now ready to lift the tank. It is helpful to run most of the fuel out of the tank beforehand, as it will be heavy. If you have not done this, get help. To lift, raise the back section of the tank up to the level of the frame, then pull back and up.

Reinstalling the tank

To reinstall the tank, simply reverse the above steps.

Testing the fuel pump

Step 1: Check Voltage at the Fuel Pump Plug

Use a multimeter to check the voltage across the fuel pump plug leads with the key turned on. The fuel pump should receive a voltage of 12V. If you are getting a significantly different voltage, there may be an issue with the electrical system or the fuel pump itself.

Step 2: Directly Power the Fuel Pump

Disconnect the fuel pump from the wiring harness and connect it directly to the battery. This will help determine if the issue is with the fuel pump or the wiring. If the fuel pump runs when connected directly to the battery, the issue may lie in the wiring, connectors, or relays.

Step 3: Check the Fuel Pump Relay

Locate the fuel pump relay, which is responsible for supplying power to the fuel pump. With the key turned on, check if the relay is clicking and functioning properly. If the relay is not operating correctly, it may need to be replaced.

Step 4: Verify Power and Ground at the Relay

Use a multimeter to check for voltage at the relay. You should have 12V at the relay contact on the fuse side. Also, check for voltage at the relay contact on the fuel pump side. If you don't have voltage at the fuel pump side, the relay may be faulty and need replacement.

Step 5: Inspect the Wiring and Connectors

Inspect the wiring and connectors for any signs of damage, corrosion, or loose connections. Pay close attention to the fuel pump plug and the main harness connector block near the fuel pump housing. Clean any corrosion with contact cleaner and ensure all connections are secure.

Step 6: Check for Fault Codes

Connect a diagnostic tool or OBD-II scanner to the bike and retrieve any fault codes that may be stored. Common fault codes related to the fuel pump include P0230 (Fuel Pump Relay Default) and P1231 (Fuel Pump Relay Open Circuit or Short to Ground). These fault codes can provide valuable information about potential issues with the fuel pump or related systems.

Step 7: Test the Fuel Pump Pressure

If the fuel pump is running but the bike is not getting fuel, you may need to test the fuel pump pressure. This can be done using a fuel pressure gauge connected to the fuel rail. Compare the measured pressure to the specified fuel pressure for your Triumph 955i model. If the pressure is low, it could indicate a weak fuel pump or a blockage in the fuel system.

Remember to consult a professional mechanic or a Triumph motorcycle specialist if you are unsure about any of the testing procedures or if the issue persists.

Replacing the fuel pump

The fuel pump on a Triumph 955i is located inside the fuel tank. To access it, you will need to remove the fuel tank from the motorcycle. Here is a step-by-step guide on how to replace the fuel pump:

Step 1: Remove the Seat and Battery

• Remove the seat by unscrewing the bolts holding it in place.
• Disconnect the negative terminal of the battery first, followed by the positive terminal.
• Remove the battery holding box bolt at the bottom and the bolts attaching the rear of the tank.

Step 2: Loosen the Fuel Tank Bolts

Loosen the rear tank bolt and then the front bolt using a long Allen wrench to avoid scratching the tank or bars.

Step 3: Remove Side Plastics and Turn Signal Plastics

Remove all the side plastics, including the black and green plastic frame covers on the right side.

Step 4: Disconnect the Fuel Sensor/Sending Unit

Disconnect the connector to the fuel sensor/sending unit. This is usually located on the left side of the bike.

Step 5: Disconnect the Fuel Line

Squeeze and pull down on the fuel line clip to disconnect it from the fuel pump.

Step 6: Lift the Fuel Tank

Get help if the fuel tank is heavy. Lift the back section of the tank up to the level of the frame, then pull back and up to remove it completely.

Step 7: Remove the Fuel Pump

With the tank removed, you will have access to the fuel pump. Remove the fuel pump by unscrewing any mounting bolts or brackets holding it in place.

Step 8: Install the New Fuel Pump

Install the new fuel pump by securing it in place with the mounting bolts or brackets.

Step 9: Reassemble the Motorcycle

• Reinstall the fuel tank by following the above steps in reverse order.
• Reconnect the fuel line and fuel sensor/sending unit.
• Reinstall the battery and secure the seat.

Step 10: Test the Fuel Pump

• Turn on the ignition and listen for the fuel pump to prime.
• Check for any fuel leaks and ensure that all connections are secure.

Troubleshooting:

If you encounter any issues during the fuel pump replacement process, there are a few things you can check:

• Ensure that all electrical connections are secure and free of corrosion.
• Verify that the fuel pump is receiving power by checking the voltage at the pump connector.
• Check the fuel pump relay and fuse for any issues.
• If the fuel pump is not priming, consider replacing the ECU, as a shorted transistor may be the cause.

Checking for error codes

When checking for error codes, it is important to use a diagnostic tool such as TuneECU to read the codes and identify any issues. This tool can also be used to clear the error codes and see if they return.

Some common error codes that have been reported by owners of the Triumph 955i include:

• P1231 - Fuel pump relay open circuit or short ground
• P0230 - Fuel pump relay default
• P0135 - Oxygen circuit malfunction
• P0463 - Fuel level circuit high input
• P0353 - Ignition coil 3 circuit malfunction
• P1353 - Ignition coil 3 open circuit or short circuit to battery
• P0352 - Ignition coil 2 circuit malfunction
• P0351 - Ignition coil 1 circuit malfunction
• P1351 - Ignition coil 1 open circuit or short circuit to battery
• P0113 - Inlet air temperature sensor open circuit or short

If you are experiencing a constantly priming fuel pump and a continuously lit engine management light, the following error codes may appear: P0230, P1231, and P1232. These errors indicate a potential issue with the fuel pump relay, which may be due to a short circuit.

It is recommended to consult a professional mechanic or a Triumph motorcycle specialist if you are unsure about how to interpret the error codes or make the necessary repairs.

Frequently asked questions