2018 Klx250s FUEL INJECTED model, bike was running like a dream first 90km when I was sitting at the gas station waiting for my friend to fuel up. I went to adjust the idle mixture screw, as soon as I touched it the bike died.

After checking fuses and connections, managed to get to a near by mechanic who checked spark, no problem, before pulling apart my fuel tank and telling me I needed a new fuel pump (I did watch him pull the metal cylinder pump part out, connect it to a battery and tell me it was broken using Google translate.)

So I got the bike home by truck, ordered a new fuel pump kit including the filter and o rings, replaced all and put fuel tank back on, and same issue. Bike won't start. When I turn the key on it doesn't prime (whirrrr) the pump, it makes a scratching type sound (see attached video).

The bike will turn over as it has since the initial failure at the gas station, but that's the only sign of life. No faults appear on display.
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Anyway, I checked terminals, fuses, connections, tried a spare fuel pump relay with Keng Engine on the phone. Checked the ignition cable behind headlight, checked the kill switch, checked the side stand switch (it's deleted) and now I am stumped...

Not sure what to do, was thinking of pulling the tank off again and looking over the pump.

Greatful for any other suggestions. Thanks

 

And if you read all that, sorry for wasting your time. The problem was a broken wire between relay and harness, where the wiring joined the harness.

Using the old chat GPT I was able to run electrical tests with nil experience and resolve the problem

 

Hopefully you didn't throw the other fuel pump away. Always nice to find an easy repair though.

 

No I have kept it as a spare 😎👍