[moto770]

I have a 2009 CRF45r that won't start. It has a new big bore cylinder and high compression piston. The head has been completely reworked and has new valves, seats, guides and has been ported and polished. New Hot Cams cam shaft and a new crank from Hot Rods.

I disassembled the top end and inspected every thing. I did find the cam wasn't installed correctly, so I installed it properly.

When I try and start it, I only get a random pop out of it. I removed the tank and put power to the fuel pump. It ran and fuel moved out of it. I removed the fuel pump and inspected it, I found it to be a later model fuel pump.

Not sure how to test the injector or the ECM.

Anyone out there had this kind of situation?

[JimDirt]

Welcome to the site !!

When you checked the pump , did you time and measure the flow , or just concur that it was getting flow ?? as it needs to pump a certain amount of fuel to prove that it has the pressure to pump enough fuel to keep the bike running ..... Though , your description also sounds like it could be timing related , I am assuming you have a manual ?? to check the flow rates and timing , or is that why you are unsure how to test the other components ??

Also , when you are cranking the engine over , was the kill switch flashing ??? , if so did you count the blinks ??? (you must crank the engine for 10 consecutive seconds)

I can post pics from the Factory Service Manual if needed to guide you thru the testing process for not only fuel but the EFI system ...

But it could be any number of things , related to fuel or timing , so more info is needed to diagnose

Here is some info to get you started:

[moto770]

I do have a manual.
I can test the pump for flow but I do not have any of the special tools for testing the pump pressure or the ECM.

I have checked and re-checked the cam timing and valve clearance's multiple times. They are with-in book spec's.

I have an extra used fuel pump (a 2009 year model pump) I installed it and still the same problem. This is a kick start only bike no E-Start . When the engine momentarily fires the "kill Switch" light (small MIL light) comes on.

I ordered the "Motion Pro" injector cleaner/tester tool. I will be receiving it today. I will then be testing and cleaning the injector, in an effort to rule it out.

I will test the fuel pump today for flow and see if I can rig up some kind of tool to test pressure.

Thank you for your response all help is most appreciated.

[JimDirt]

If you look at the troubleshooting page I posted above , it IS for kick start bikes (09-12 Factory Honda Service Manual) , as the button did not come till 17 as a option only , so this explanation is for kicking it for 10 seconds consecutive to get a result