Hey guys!
I signed up here to hopefully get some better feedback and direction than I have been getting with this issue. I've had my 05 cbr for about 6 months no with no issue until last week. I was warming the bike up and suddenly it died on me like it ran out of gas. When I tried starting it again, the lights would come on, the fuel pump would not prime however and the fuel gauge would do this dance where it starts in the middle and spreads out to either end. In the owners manual it says it's a fuel system error and to take it to your Honda dealer. I went through and cleaned all the connections to the fuel pump and checked all the wires. I checked the relays and fuses as well and they all are good. The only way I can get the fuel pump to prime and the fuel indicator to not do that dance is by pulling the gas tank out of the bike and sitting it on the frame. When the gas tank is down in the bike, the fuel pump doesn't prime and the gas gauge freaks out. I pulled the fuel pump out recently and all the wires look intact and nothing is gummed up. When I had the gas tank in the bike, I can wiggle it side to side with the bike in run and get the fuel pump to prime and then stop priming. The other day I was able to see works coming from the gas tank to the frame when it's sitting out of the bike. This is definitely not safe! I think my next step is to trace the grounds from the fuel pump and check that they are connected. There's a live wire where there shouldn't be. Any help and input would be greatly appreciated. Thanks! Help me get my baby working again ):
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Did you check the battery?

 

Yeah it's putting out about 11.6V if that's what you meant by check the battery.

 

11.6 is not enough. How low does it go when you turn the key on, then try to crank it?

 

I haven't tested that. So for a 12V battery, it should be outputting more than 12V?

 

It's not a 12v battery. It's a 12.8v battery. It should be charging at 13.5v to 14.5v. Since your standing voltage is at 11.6v, I'm betting that when you hit it with a load, it will go flat. When the voltage gets low, the electronic stuff, like the ECM, have trouble or won't have enough voltage to work at all.

 

I mean Ive been turning the electric on and off for the last few days and running the fuel pump without really recharging the battery. Could that be the reason?

 

Could be.

All electrical diagnostics start with checking the source.

 

True, I will definitely check that but that doesn't really explain the sparking from the tank to the frame.

 

I found this which definitely looks like the ground box was melted. I've read of people just splicing all the grounds together and wrapping it in shrink wrap or electrical tape. Is that the best option? Or can I find another connector somewhere?