Air filter?
 

Do check the air filter again even if it is brand new (that is unless it is so brand new that you installed it now, not 100km ago). It's amazing how much crap can get on the filter in no time at all if one drives on dusty roads.

I hope someone can help you with the whereabouts of the fuel filter, you should check that too or even better, just replace it if a generic part fits. I would also flush the whole fuel system if that's a possibility, it might be hard to get all the dirt out of the fuel tank if it really is the problem. I have never cleaned an injector on the road (I have been stranded by a blocked one once), but even carbs are nasty enough to clean at the roadside.

Even if you get a strong spark, change the plug anyway. BTW. how does the spark plug look like after trying to start? Wet, dry and what color? Wet -> no air or no spark. Dry -> no fuel. Black, too rich -> too little air.

Take care and good luck!

I hope the fuel filter on an xt660r is not in the same place as the tenere: in the fuel pump, in the gastank, because then you have a problem. So first try to locate the fuel filter. When you changed the fuel in the tank, was the old fuel dirty? Then try starting without the air filter (don't drive it without the filter) and change the sparkplug.

The plug is dry when i try to start it, suggesting no fuel. Would this support the idea that there is a blockage somewhere in the fuelling system? I replaced the spark plug already.

When I drained the tank, there was a bit of dirt and the fuel smelt a bit funky.

I took out the fuel pump and took it apart as much as is possible. The filter is inside the pump (assuming the filter is the square tea-bag sort of thing that points down the way, and seems like it is integrated into the fuel pump (can't be taken off, as far as I can see).

The pump itself sounds like it is working fine. I'd like to isolate the problem. How can I test that it is sucking up the fuel and passing it through the hose? Would placing it in a bowl of gasoline then connecting it up be okay?

If it is a blocked injector, how would I go about cleaning that? I don't want to damage any components.

Also, one other possible source of problem: I notice the part of the tank/pump unit that the hose joins onto (I think it is meant to be an L-shape) has at some point been broken off, and a metal nozzle sealed in its place. A 4 inch rubber tube then joins this nozzle to the fuel injector. Could this be part of the issue? it has run with this set up before, though never at its best.

Thanks for all help so far! i really need to get this bike moving.

You have found the fuel filter, yes it's the tea bag on the pump.
If there is any watchmaker near you, you may take the entire injection unit and bring it o the watchmaker for ultrasonic cleaning. The Injector nozzle itselve may be clogged, take it out and let it be cleaned by the watchmaker as well.
Check the fuel pump without the fuel line connected, - take care though, if the pump is free, it will produce quite some pressure!

good luck!

How did the story end?
 

I assume you got out of there? How did you do it and what happened?

Hello again, sorry for the slow response and thanks for the guidance so far!

I'm still in Liberia, and the bike still won't start. I did some more tests, and I would like to hear what people think:

1) I took out the injector. It seems to work (sprays gas when I hook it up to battery)

2) i took apart the fuel pump. the fuel filter is not blocked. the fuel pump is running, as in, the diagnostic system finds no problem, and it vibrates when i test it. however, it doesn't seem to be sucking up any fuel. I tested it out with the hose disconnected, and no fuel spurts out. I can feel no suction running it dry, outside the tank. fuel drips out, but that happens whether the pump is connected or not.

So, it would seem to me that the pump is the issue?

Is there some way I can get fuel into the engine to see if it will start, as I would with an old bike with a carburetor? I want to test if the fuel pump is the only barrier to starting, or if there is another issue.

Also, is there somewhere in the UK/Europe where I can purchase an XT 660 R fuel pump? I would have it shipped out to Liberia, but I looked online and couldn't find one for sale anywhere.

Thanks again for your help. Look forward to guidance on the above!

Fin

I hope this price is a mistake: 870�
XT 660 R fuel pump

If 870 pounds is accurate then I'm in bigger trouble than I thought! I can't find one for sale currently anywhere.

BUT, I have found one very similar which is more widely available. The fuel pump on the XT 660 R is a 5PW 13907-01 I think. Now, you can find a 5VK 13907-01. It is for the R1 to R6 range of yamahas apparently. It looks very similar. Are these things interchangeable, or will I need the exact one for my model?

Apologies for newbie questions, but I don't know that much about yamahas at all.

One other thing: does my reasoning in the previous post seem indicative of a faulty fuel pump? And is there some way to check definitively if this is the only fault?

I'm quite desperate, so if you have guidance, please offer it!

Thanks

Quick post - sorry not too much help with the technical stuff but ......

My XT660R parts book would indicate that the fuel pump part code for the (european) version is indeed 5VK-13907-02

I assume this is just a slightly later version of the 5VK-13907-01 model.

There have been some previously on ebay at around 200 pounds but nothing showing available at the moment :crybaby2:

Hope this helps. Good luck.

Came across these guys - worth a try

http://www.kedo.de/

And scroll down to the new arrivals and search under the XT660X/R/Z choice - up pops a fuel pump and its in stock - sounds like you would need a separate filter tho.

Too cheap to be true I know, but might be worth a phone call.