This will be a long post so bare with me. I purchased a 2001 zx7 from a guy that had it sitting in his shed for 3 and a half year, WITH GAS STILL IN IT. I managed to put the bike all back together, pulled the carbs and tank cleaned and flushed the lines. After finding the pilot jets completely stopped up, I managed to get the bike to idle and run ok. I found the harness connecter from the ignition switch under the air box to be melted a little. I spliced and redid the connectors. Anyway, once the bike runs for a while, temperature is normal on the gauge, but the bike feels pretty hot, the fuel pump quits pumping and you would not be able to restart the bike. You have to hit on the junction block to get it to spin over. So far I have replace the junction box, fuel pump relay, starter sylonid with no luck. When it dies I can power the pump with my power probe and the pump works. I pulled the pump off the bike and check operation and it shows to be good. Good pressure and volume. I think Im losing voltage when it gets hot. I just cant find where. All grounds have been checked. Cant find anymore melted wires. No one can tell me what the pump voltage should be when the bike is running. The wire that comes from the relay to the pump varies in voltage. 6 to 8 to 11 to 4. The power coming into the relay is battery voltage. I had a fuel pump relay from a zx6, same part number, same voltage so I didnt think that was the problem. The bike has left me on the road 4 times. Its runs awesome until it gets hot, like stuck in traffic. Takes about an hour or so and shuts down. Let it sit and it cranks up like nothing is wrong. PLEASE HELP!!

 

From what whitey has mentioned in here ( the forums) that the relay is prone to failure. A bad connection to be solved right there. Welcome to KF. let us know of course on the outcome.

 

Welcome to K.F.

 

+1^^^