My 97 TLS won't start. I replaced the fuel pump because it was seized up from old fuel in a hot climate. The replacement seems to prime ok but when I crank it over, I get no spark. Have tried a little ether in the airbox and it does spark for a few seconds so I am guessing it's fuel delivery. Is it possible the injectors are also gummed up? Appreciate your collective wisdom.
TLS Fuel system issue
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Could be a lot of build up in the lines and the fuel injectors. Do you have a manual? If not, go here and get one, Steve's TL1000S pages There's a test in there you can do to find out if you have the proper amount of fuel pressure.
Make sure your tip over sensor is mounted correctly, and plugged in. Has a white two wire connector, and the sensor wires are black, and black with white stripe. Mounted by the Vacuum damper, in front of battery. I left mine unplugged by mistake, and same thing. Sparka, and fire injectors a couple of times then stop. Backfires, etc.
+1 on the TOS.
PezTLS, If you have verified that it only sparks for a few seconds, the TOS is likely the problem. It should generate an error code, but not always.
It takes the ECM a few seconds to process the TOS error. Then it stops ignition and fuel delivery.
Clogged injectors won't prevent the plugs from sparking. Of course, the injectors may still need to be serviced, but they are not preventing the spark.
OK thanks so much for the tips. I checked the TOS and it is mounted correctly and still plugged in. I checked fuel pressure as per the manual (yes I downloaded it and it's really helpful). Didn't use a pressure gauge, just removed the fuel pressure check bolt and turned on the ignition (had a container ready). Plenty of fuel pumping out at decent pressure. The only test that didn't seem to work was the 'fuel discharge amount inspection' on p289 or 4-51. I'm not sure which is the fuel return hose. I tried the one with a coil around it like the picture but I think that's the feeder hose from the tank.
Still firing up if I spray ether into the air box but not otherwise. And I don't want to make a habit of the ether as i think it's not friendly to the engine.
Any other suggestions?
Still firing up if I spray ether into the air box but not otherwise. And I don't want to make a habit of the ether as i think it's not friendly to the engine.
Any other suggestions?
Pez, The fuel return hose is the one between the pressure regulator and the fuel tank. It is the smaller diameter hose, and it usually has a spring around it. The "feeder hose" or the pressurized incoming fuel line, has the blue retaining clips on each end.
If you can get 30 ml of fuel coming out of the return line during the prime cycle, the fuel pressure is likely OK.
The fact that it starts when you spray ether directly into the throttle bodies is a strong indication that the injectors are clogged up. It is unable to deliver the fuel it needs for startup.
Now that you have the shop manual, have you checked for other error codes while you are cranking it over?
Pez, I'm sorry for the long delay. I was out of town with many distractions. 🙃
I must disagree on your injector suspicions. True, they may need to be serviced, but they are not preventing the fuel from flowing through the return line.
In order for the fuel in the rail to return to the tank, it must pass through the fuel pressure regulator (FPR). Since you are seeing no fuel from the return line, that says the pump pressure is inadequate. The pump is running, but it is weak. I have experienced the same issue on my TLR.
If the pump can't generate enough pressure to open the FPR, then it is also providing low pressure to the injectors. That's why the engine won't start as it should, and you need the starting fluid to bump it over.
The FPR is a simple spring loaded valve, and it rarely fails. Therefore, the most likely problem in your system is one or more of the following:
- Weak fuel pump
- Clogged fuel filter
- Perished fuel lines inside the tank.
Let us know what you find please.
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More importantly, he said it runs off starting fluid. The old school test was remove spark plug, hold the body against the head, crank, look for electricity.
If anyone reads this forum... Please do not say
My definition and I think everyone here would agree "does not get spark" means the spark plugs are not firing. Sputtering from fluid means the spark plugs are in fact firing.
You have a no start condition. Not a no spark condition.
Like six said, if the return test fails. It's a fuel delivery issue. What brand pump did you buy???
Sorry for the delay in getting back - life got in the way. But I found a youtube video showing how I could set up a little test rig. Turns out the injectors were fully clogged. Also turns out they really don't like old fuel sitting in them in the tropics. Then the local shop told me Suzuki wasn't selling 97 TLS injectors any more. Luckily they were able to clean them. So I reinstalled and she started almost first time. Thanks Six5 for the good advice. And to the others, I will be more precise next time I talk about no spark vs no ignition 
Pez, Thanks for the feedback on the ultimate fix. It's always nice to know what the real problem was. Better late than never.
However, I'm still wondering why you didn't get any fuel from the return line...
Glad you got it back on the road.
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