Honda Hornet keeps on cutting out

[chris 4624]

I have recently bought a 1998 plate Honda Hornet 600cc with 22,000 miles on the clock. It drove like a dream back home for 140 miles. Whilst the bike was sat in my garage for about a month I changed the oil filter/oil and the battery.

Once I passed my test it took her out for a spin and she started first time. I rode for about 80 miles without incident. Parked the bike up for 10 minutes jumped back on and it lasted for about 8 miles before cutting out. There was plenty of life in the battery it just wouldnt catch (as if it was out of fuel) Finally after about 10 minutes it started, rode for about 2 miles before doing the same thing. The temperature never went above the 75% mark. I had been running on the reserve tank with about half a tank of fuel.

Once I got back home I switched it from reserve to on and filled her up. The next day she ran for about 50 miles before cutting out AGAIN! I realised that petrol was leaking from the pipe leading from the tank to the carb. I fixed this problem and thought that the problem was solved. The bike then ran for 100 miles without incident. I then parked her up in the garage.

The next morning I jumped on her to got to work with all the confidence. After about 4 miles she cut out on the motorway. Pulled over to the hard shoulder and managed to get her started after about 10 minutes. She only lasted for 1 mile. I then called for recovery. I attempted to start her again after about 40 minutes with no joy. However the next day she started with no problems.

I dont know where to go from here!! I only passed my test on Thusrday and am itching to get her on the road. However cant afford to put her in the garage just yet.

Can someone please tell me that the problem is cheap quick and easy to fix?

Thanks

Chris

[garth]

Bear in mind that the hornet tank range is utter utter shite, you're claiming 100+ miles and then cutting out, wouldn't surprise me if the tank is empty.
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You ain't a has been if you never was

[petemell]

Hi Chris, I reckon it could be a dodgy fuel tap.
I think it is the diaphram type on this bike, therefore the fuel is only turned on when the bike is running.
But it sounds like it is turning the fuel off while the engine is running, causing fuel starvation and cutting the engine out.
Perhaps a new fuel tap or fuel tap diaphram would cure it.
Hope you get it sorted.

[FerretFing]

Hi, there will be a cheap & easy way to fix it I`m sure. When you say you fixed the leaking fuel what did you do exactly? and can you describe how it was leaking - e.g. was it a split in the pipe etc

[m0l0t0v]

I had a very very similar problem on my Hornet. It was to do with the fuel tap. Wasn't the tap itself but the rubber hose that connects from the back of the tap (which is where the diaphragm is) and connects to the manifold of the engine. Look and feel the hose and see if there's any marks or holes on it. That hose is used for pressure so it pulls the diaphragm out and lets fuel flow into the carbs. When I found out what it was (after leaving it securely locked in the middle of nowhere for 5 days) it took a total of 3 minutes of finding out what it is/was and sorting it out. I literally cut the end of (where it had tarnished) and put it back on! Voila. Simple as.

And yes, the Hornet tank range is aweful so don't expect anything above 100 miles to the tank.

If that isn't the problem then take the tank off the bike (bit of a fiddle job unfortunately, much much easier if you have a friend to help) and then remove the fuel tap (having the tank upside down over a towel). Then have a look at the tap and check the diaphragm and see if it's damaged at all. If it is damaged (any holes or gaps/whatever) then it can't create pressure and wont let petrol flow.

Also, you won't have to worry about petrol leaking when you take the tank off.

Hope that's what it is! Also, while the tank is off have a quick check on the spark plugs.
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'99 Hornet 600 , VFR 400 NC30 '92 , Kasawamasaki GT 550 , '98 Hornet 600
**\Tarmacsurfer/** said: It's that immaculately manly coiffure of yours isn't it. One glimpse of your virile locks and the punters can't wait to buy whatever it is you suggest, as it might let them be just a little bit like the Adonis that is our very own Molly Doovydoo said: Its not my fault I can't get it up properly, I just wasn't blessed

[chris 4624]

Thanks all

I think I was just being stupid and run out of fuel! HA! (even tho there seemed to be only just under half a tank of fuel.)

She is running great again now I have filled her up.

Will keep on top of it from now on and hope that it is the problem.

You are all right, the fuel tank capacity is S**T.

Thanks again

Chris

[nsimmons74]

Hi Chris,

My hornet is experiencing the same problem as this. Are you sure you simply are running out of fuel.

I filled my tank, rode on and off for a total of about 65 miles - then it suddenly would not start one day. I had just ridden it to the gym about an hour and a half ago - after I'd finished and jumped back on the bike to go home it just wouldn't start.

I turned the fuel to reserve - still no joy. Left it for 10 mins, tried again, no joy. Put the fuel back to ON and tried again, still no joy. By this time I'd worn the battery down trying to start it.

I called the AA - they took about 30 mins to arrive, the AA bloke put a battery charger on and we fired the bike for about 30 seconds (fuel still set to ON) and it started fine. I then rode it 5 miles home, and then again rode it 4 mles into work this morning. I have no idea why this is happening - has yours cut out again since your last post?

Thanks,
Neil.

[temeluchus]

any better on prime?
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Some shite cruiser. Now with guns and FREEDOM!

[nsimmons74]

Sorry, I'm not sure what you mean...

[temeluchus]

Does your fuel tap have a "prime" position? This allows the tap to run all the time, so if you have a faulty vacuum tap it will allow it to work.

Alllllso, when the bike cuts out pop open your petrol cap and listen for a hiss-your cap breather may be blocked.
____________________
Some shite cruiser. Now with guns and FREEDOM!

[nsimmons74]

Hi, it doesn't have a prime position, just ON, OFF and RES settings. It's a year 2000 bike if that helps.

I didn't hear any hissing noises when I opened the tank...

[That_Hornet]

Tank off and check all the hoses. Try and find any cuts, holes and slits.

Check everything is routed properly.

:UP:

[madmanrider87]

Hi guys, i had the exact same problem as chris is describing on my old hornet, it turned out to be the filter on the tap inside the tank, the vacuum from the engine had actually crushed it where it was tryin 2 pull the fuel through, all i done was take the filter off and threw it away and ive never had a problem since, never cuts out and doesnt even cause my pal any trouble who bought the bike from me, try that because to be honest providing you keep an eye on your fuel levels you dont really need 1.....
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(PAST) - Hyosung Comet, R6, CBR600, R1, Hornet 600, (PRESENT) - Hornet 600

[corrsfan]

thanks guys. just saved my backside with this thread.

i was about to call the aa, as its at my parents being stored so is more than 1/4 mile away from my address...
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passed 125 test mod 2 - Nov 12
selling '12 cbf125 march 13, for a restricted 5/600.

[Scotsman37]

Wow, I used to own the Hornet 900 which was the best bike i had ridden so far with reasonably good mileage from the tank with 3 full tanks for a 700 mile journey, quick off the mark, mechanically sound, started up immediately and gave me no electrical problems what so ever! it was a little bit top heavy, but I quickly adjusted to it and it was a good overall bike!

Sometimes with the bigger bikes if someone installs an inline fuel filter you have to make sure it is suited for that cc of bike and not say for 125 instead because it will cause fuel starvation. Also, watching out for the potential of fuel tank rusting inside or blocked air hose breather for the tank can reek havoc in the end. So like others do on here regular maintenance and watch out for problems to prevent them from becoming bigger ones!