a big thank you to burner who posted the autozone part numbers a while back. it turned a $250 OEM replacement job into a $135 job. the part number for the fuel pump is E8213. i did the work on my buddy's bike that when i got it was running at 12 psi. once it was cleaned out and a new pump installed, its running right at 50 psi. if you don't have a fuel pressure gauge, i highly suggest investing in one. mine has given me the peace of mind when i thought something was wrong and helped me diagnose a few bikes now. well worth it and they are pretty cheap.
first off, if you need help getting the pump out of the tank, i highly advise that you let someone else fix your bike from now on. if getting the pump out is an easy task, this shouldn't take long at all. i'm not going into the steps to get the pump out as that is very straightforward. the whole process is, but pictures do help some people.
here's what you've got when you remove the pump assembly:
make sure to clean it off real well. i got lucky in that someone else had already flushed the tank and cleaned everything off.
here's the pump from autozone:
all you need from the box is the pump itself and the metal retainer for the filter:
start by carefully removing the bottom cap. there are three points where it is held on. just use a flat blade screwdriver to get it off:
note the junk just in the bottom cap. once i saw that, i knew there had to be more in the pump. thankfully i was warned that there was junk in the tank and when i talked to the guy who cleaned it out, he said the filter was darn near solid with crud when he pulled it out and the tank was filthy.
snip this zip tie to give more slack in the wires going to the pump:
remove the gray plug from the top of the assembly by prying the metal locking tab out of the way:
remove the plastic body that is around the fuel pump from the black piece. like the bottom cap, there are three retaining points:
push down and slide the metal piece towards the top of the assembly to remove:
here's the stock pump vs. the aftermarket pump:
pop the connector off the stock pump:
slide the plastic plug and hard washer off the stock pump:
pry the filter off the bottom of the stock pump. use a flat blade screwdriver and work your way around it so you don't damage the plastic. i pried from between the pump and the plastic, not the plastic and the retainer:
pry the filter off around the inlet hole:
the pumps are a little different, but not enough to make a difference:
slide the filter on the new pump and use the retainer that came with the new pump. the stock one might work, but its on a plastic post vs. the metal post of the aftermarket one, so i decided to use the one that came with the new pump:
the plastic plug and washer won't stay on the new pump since it doesn't have barbs on it, but it has to be installed for it to work:
plug in the new pump and slide it into the plastic housing:
make sure that the outlet of the new pump lines up with the regulator:
slide it all together and make sure the black wire goes through the tab on the white housing and make sure the parts lock together:
pull the metal piece back into place:
pop the endcap on and the replacement is finished:
now here is why you should check the regulator on a regular basis:
that came out when i removed the fuel pump. the darker particles are probably from this area of the country.
then i blew back through the regulator and this came out:
the lighter particles are probably from the last time my buddy was in texas.
i soaked it in parts cleaner for a while and blew some compressed air through the regulator and kept doing it until what came out wasn't looking like mud:
when i used compressed air to go in the normal direction, no particles came out. but in the reversed direction was when i got all the junk out of it. that leads me to believe that it has some sort of built in filter on it, so inline filters aren't as necessary as i first thought.
to get the regulator out, just pop off the metal band that connects the two black pieces:
all this mess was caused by the gasket in the gas cap not being seated or something like that. so make sure your gas caps are in good working order. but in the event you're not getting enough fuel pressure, i would suggest first cleaning the regulator. if that doesn't work, replace the pump.
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