ok will do thanks...relay cost �47 ...not so bad after all...cheers and again thanks

hi ..relay arrived today fitted it turned on ingnition ..ok then pressed the starter .the fuse blew...i was wondering if i should... try it without the tank fitted..to see if the fuse would blow that would take the pump and fuel level unit out the circuit

Sounds like a plan. No need to remove the tank. Just remove the mounting bolts and lift the back up, propping it up just enough for you to detach the wring connectors on the pump/sender unit underneath.

Try it with the pump disconnected, obviously it won't run, but see if the fuse stays intact...

tank on bench already...i will try it and see
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ok tried it with the tank away from the bike..switched on ,fuse ok...pressed starter fuse ok....done the same again ..fuse blew upon pressing starter..repeated with another fuse and it also blew....

So, just to clear things up, it's now blowing as soon as you press the starter?

morning...yes with the tank away from the bike...i turn on ignition.fuse holds...switch off ,turn on fuse holds..press starter fuse holds .press again fuse holds .press again fuse blows.......
....another thought maybe i could detach the electrical connector to the injector and like the tank see if a fuse blows with it out of the picture ..not leaving much left on the FI circuit again thank you

tried again today...fuses blew and held sometimes with the injector diconnected some times with connected ...then battery began to weaken with turning over the starter...charged the battery .fuses seemed to be holding..started the bike with tank back on and all connected.. no fuse problem ran the bike for a couple of minutes .stopped and started it and ran it a few times more...then after running the bike for about a minute i gradually revved
it up to 4 k and then the fuse blew...thought i had solved it by some accident but it let me down again...it may be the pump after all...or could it be the regulater ..but would that not blow fuse 4 (i would pull my hair out if i wasnt bald)...returned to bike once more..put in a new fuse ..blew upon turning on ignition and before pressing the starter ...blew another fuse the same way moments later.?????????????????????

It could very well be the fuel pump still. I take it you haven't tried the new one yet?

I know you said you'd checked the wiring, but are you double sure the wiring spur to the injector is good? By the random nature of the problem and the fact you say it worked sometimes and not others with the injector disconnected it sounds like other instances where this wiring has been the problem. It is, as I mention earlier quite a common problem on the Z. The revving of the engine to 4K may be causing an abraded wire to make contact to earth - 3.5 to 4K rpm is after all where the 660 motor vibrates most. You've already checked the output of the alternator and reg/rec unit and it was within spec.

I don't think using a diagnostic tool is necessarily going to be much help with this one, but still may be worth having a go with if you can acesss one.

Try the new pump and go through the wiring again with a fine-tooth comb.

ok will try all of the above....thanks again...