Step 11: Now remove the old fuel pump connector by cutting the connector off. Crimp on new spade connectors onto the fuel pump wires. Positive is red and ground is black. The positive and negative is marked on the fuel pump. Reconnect the fuel pump wires and reassemble the unit. (Gasoline is dielectric, just means it doesn't conduct electricity) Just reverse the instructions for separating the fuel pump from the unit to reassemble.

Step 12: Make sure the unit is assemble correctly. Till the unit until the fuel level arm is 90 degree's point towards the floor. Insert the fuel level arm into the fuel tank first and then slowly wiggly the unit back into the fuel tank.

Step 13: Before bolting the unit back onto the tank, make sure the fuel port is facing the right way.

Step 14: Apply lock-tite to each of fuel pump unit retaining bolts and tighten down to 7lbs in a crisscross pattern. 7lbs is hard to measure so hand tight.

Step 15: Reattached the tank back onto the bike by installing the rear tank retaining bolt first.

Step 16: Reconnect the fuel line back onto the fuel rail. Press the line back onto the fuel rail and make sure the green tabs are lineup with the open space on fuel line connector. Once a click is heard, the line is attached properly. Reconnect the fuel pump harness by pressing both ends back together until a click is heard.

Step 17: Reinstall the battery. Power on the ignition and set the run switch to run to pressurize the fuel system. DO NOT START THE BIKE. Check for leaks and if no leaks are found start the bike. Let the bike run for a few minutes while checking for leaks again. Once no leaks are found, shut off the bike.

Step 18: lower the tank and reinstall the front tank retaining bolt, reinstall the fuel tank trim pieces and reinstall the seat. All done.

Hope this was helpful, happy holidays and ride safe.

 

Step 11: Now remove the old fuel pump connector by cutting the connector off. Crimp on new spade connectors onto the fuel pump wires. Positive is red and ground is black. The positive and negative is marked on the fuel pump. Reconnect the fuel pump wires and reassemble the unit. (Gasoline is dielectric, just means it doesn't conduct electricity) Just reverse the instructions for separating the fuel pump from the unit to reassemble.

Step 12: Make sure the unit is assemble correctly. Till the unit until the fuel level arm is 90 degree's point towards the floor. Insert the fuel level arm into the fuel tank first and then slowly wiggly the unit back into the fuel tank.

Step 13: Before bolting the unit back onto the tank, make sure the fuel port is facing the right way.

Step 14: Apply lock-tite to each of fuel pump unit retaining bolts and tighten down to 7lbs in a crisscross pattern. 7lbs is hard to measure so hand tight.

Step 15: Reattached the tank back onto the bike by installing the rear tank retaining bolt first.

Step 16: Reconnect the fuel line back onto the fuel rail. Press the line back onto the fuel rail and make sure the green tabs are lineup with the open space on fuel line connector. Once a click is heard, the line is attached properly. Reconnect the fuel pump harness by pressing both ends back together until a click is heard.

Step 17: Reinstall the battery. Power on the ignition and set the run switch to run to pressurize the fuel system. DO NOT START THE BIKE. Check for leaks and if no leaks are found start the bike. Let the bike run for a few minutes while checking for leaks again. Once no leaks are found, shut off the bike.

Step 18: lower the tank and reinstall the front tank retaining bolt, reinstall the fuel tank trim pieces and reinstall the seat. All done.

Hope this was helpful, happy holidays and ride safe.

I'm at autozone trying to buy an accura or honda fuel pump and these guys are saying no way ,they are way different....whom ever told you that is high.but they both look high to me. So it really fits rite in other than cutting that one spot?

 

Thanks for all the pics and text. It really helps knowing how the bike is put together.

 

:thumbup

I like it. Finally, someone had a coherent thought when modding the bike.

Before, hurr durr why e85z!!!

E85 will require more changes than just the pump because of its alcohol content, but, the possibility to add compression and timing while using "pump" gas has potential here. Gas mileage will drop, but if tuned for it, the bike could wring out some more power. I like this potential for a track bike.

 

Well first to address the concern of the alcohol content of e85. Yes, alcohol is corrosive but most cars and motorcycles after 1990 have no issue with running e85. My friend daily drives is 600hp turbo mr2 with no issues. Most manufactures thought of alternative fuels and knew oil was not going to last forever. Plus ethanol has been around since the 90's its just wasn't big like it is now. Our fuel tanks are steel and so are our fuel rails. Our fuel line from tank to fuel rail is harden rubber and it should not have a problem with the alcohol content.

I live by a e85 station 3 blocks away and there are bunch on the way to work. The bike will be setup for flex fuel, which I can run regular gasoline or e85. I pick up a set of rc engineering fuel injectors 410cc for the use of e85. E85 requires 15-30% more fuel then gasoline because its energy output is less. Therefore requiring bigger fuel injectors. The fuel pump is a walbro 255lph which will supply more then enough fuel for what my 600 can make.

One might ask why use e85 as fuel when it is less efficient? The ability to run more ignition timing to make more power and torque. E85 is about 105 octane and premium gas is 91 octane here in CA. E85 cost 2.69 a gallon here while Premium gasoline cost 3.34 a gallon. Alcohol fuels also introduce a nice cooling effect into the combustion chamber. During part throttles I can run leaner afr's which will help with gas mileage. As for my fuel management system, its a secret for now. All in all, I wanted to try something different. It might not be worth to others but for myself it is. I like to go after the impossible and challenge myself.

 

Just wanted to say i have just fitted the Honda Integra pump to the K2 GSXR 1000 and it all fits very well and works great just like described above. Thanks a lot for posting the info and all the pics. Saved a fortune on the new pump. This should be saved as a reference somewhere for others.

 

now that we know that non-Suzuki pumps will fit, how about non-OEM fuel filter? that is, if civic's pump can accept suzuki's fuel filter (of course if OP reused his stock fuel strainer), couldn't it be vice versa? price difference is palpable
PS I'm talking about mesh filter

 

Cant use the Honda filter. Too big. Dont need to replace the mesh filter, just clean it. you can clean the main filter as well. Just used carb cleaner and flushed with water.

 

Hey there I was wondering if you guys think that the civic pump will work on a older model gixxer 600?? have a 2000 that the fuel pump went out on and dont want to spend the big dollars on the OE pump

 

tried this on a 02 750 major fail pump bike won't start pump seams to be working fine pulled the fuel line and fuel keeps coming out kept going until tank was empty now i'm wondering if pump spins both ways and polarity is wrong idk .

 

Has anyone done this for an external fuel pump mod? Doing this on my track bike with fibreglass gas tank with in-line glass cylinder filters.

 

Old thread but does anyone know what models and years this applies to?

 

Firstly, thanks to Jayknight for taking the time to post this in such detail - very useful!

The information is relevant for a range of different modern bikes - I can confirm that even BMW R1200GS's use a similar Bosch unit. So to echo Jayknight's advice - exercise due care, remove your pump as described and get to the bronze pump bit ... which will have a model number / manufacturer on it. Source a new replacement from a car auto store and viola! $400 saved

 

I too appreciate the post, I have used it. However, I paid $33 for a replacement pump at Axiom Performance/High Flow Fuel Systems. Both are on eBay but you do not realize they are the same company.

 

Hello everyone, I havent been here in ages. Im glad everyone is finding this info useful. Enjoy and happy riding everyone.

 

Jayknight, it's a handy thread man. i'm about to build a pump for my bike, just gotta get the some crimp connectors. i'm gonna try flag connectors so i don't have to bend the prongs on the Walbro and i'm thinking they should clear the housing. the only information i would add is the Walbro model#. i heard it was GSS342, so that's the one i got. maybe you can confirm that.

 

Will this work on a 2008/2009 GSXR 600/750?

 

The electric pump motor was changed (smaller) for the K8 model onwards.

Usually it's the main filter (not the pre-strainer) that clogs long before the motor fails.

 

Tank doesn't have to be emptied first?