Just replaced my handlebars and ened up taking the tank off to get everything tucked away. Put everything back together and now the bike won't start. Turns over but just won't fire. Any direction would greatly help.

 

When you turn on the ignition can you still hear the fuel pump activating? Check all connections again, make sure you did not kink any of the wires when you re installed the hand controls.

 

Fuel pump definitely turns on and activates. All hand controls are working. Turns and turns but does not fire.

 

Question: did you properly re-attach your fuel line?

 

What he said.

 

What is the process to properly re attach the fuel line? Definitely getting spark but no fuel. There was a plastic tube attached to the line that I pulled out a little and tucked it back in and tightened it back up. Thinking this much be my issue at this point. Thanks!

 

What plastic tube? Can you post a pic so we can help a bit more?

 

I think I know what happened here. I'm getting the impression that you actually unscrewed the fuel line from the tank instead of just pulling off the quick disconnect. If that's what happened the plastic tube you pulled out of the inside of the tank through the hole in the bottom of your tank is the hose that connects your fuel line to the gas pump inside the tank. If this is the case there could be a few different reasons that you aren't getting fuel to your injectors; you could have kinked the line inside the tank, you could have bent it and twisted it enough that you pulled the connection at the pump end so that it isn't properly seated, you could have ended up putting a pinhole in the line inside the tank which would cause you to lose pressure, and there are probably a few other things I can't think of right now.

So I guess the question now is what you mean when you said you unhooked the fuel line from the bottom of the tank: did you unscrew something or just unhook a Q/D?

 

Aside from the fuel line, did you check all of your fuses? Had a similar issue once, turned out that while reconnecting the battery I had inadvertently grounded something out and blew a fuse. Happened to be the ignition fuse, fuel pump primed and everything turned over, but no spark. Check your fuses....


Ok, this does worry me a bit. You say you removed the tank, not just slid it back? And that you saw the in-tank line when you did this? When you removed the tank, did you pull the plastic line completely out? Even if not, the plastic line is factory fused to the disconnect, and tightly crimped to the fuel filter. If you spun it enough times to remove the Q/D fitting from the tank, then you've probably twisted the life out of that plastic line and its either cracked or loosened itself from one of the connections. $50 part, PITA to replace.

When you are at the dealer picking up the parts to fix this, get a manual as well.....

 

Knowing there was a quick disconnect would have made this much easier! You are both on it, inside line going from quick disconnect to fuel pump was twisted to the point no fuel would go through. Got the new part on order. Fuel pump is a pain to remove thus far. Thanks for the help.