bwallis42
Registered user
The pump arrived as a kit that I assume is for a number of bikes as there are more parts than I needed. The next picture shows the kit parts and indicates which ones I used, basically just the pump, a hose clamp and the screen for the intake.
First thing to do is remove the pump unit from the left side of the tank. You will need a tool to undo the clamp ring, I made one (see the last picture below). Carefully remove the whole pump unit from the tank, if you have a mechanical float style fuel gauge like my '05 GS be careful you don't bend it on the way out (or in).
With the whole unit on the bench, unplug the power connector and then unclip the three rubber mounts as shown in this (unfocused) picture.
Next remove the hose clamp on the pump, I used a (cheap copy) of a dremel to do this.
Heat the hose and remove it (it was very cold the day I did it).
To remove the pump from the housing you will need to remove one of those push on star washer things that holds the pickup filter screen. Prising it off would likely break something so I used the dremel again to grind off the top of the post on the end of the pump. You also need to remove some of the plastic of the pickup filter to get to the post.
After removal of the pickup filter screen.
The pump should now just push out the top of the holder if you pull back the two plastic clips.
Here are pictures of the old and new pumps.
As you can see the replacement pump is a good copy of the original VDO pump.
Next push the new pump into the holder and align it before fitting the pickup filter screen. This just pushes on and then you press on the new star washer clip thing. I found a very small socket and used that and a small hammer to tap it onto the post on the end of the pump.
Put the hose back on and secure with a hose clip, clip the pump unit back on to the holder with the three rubber mounts and plug in the power again.
Now you are ready to install the pump unit back into the tank. As I have found out this can be a bit tricky if you don't get the seal done right. It is quite easy to crimp it and end up with a leaking tank. Very embarrassing at the service station when you fill up, trust me :-(
I grease the inside of the filter seal with vaseline to make it easier to get the pump in without dislodging the seal.
The next photo is of the seal in place ready to install the pump. Note the fuel return hose visible at the top of the hole. This is the hose from the sucking pump on the RHS of the tank. (yes, the tank was rather full when I did this repair).
Then after inserting the pump unit I check very carefully around the edge to make sure it hasn't pushed the filter into the tank. You need a mirror to see all the way around.
Now fit the ring and torque down to 35nm. This picture shows the "special tool" I made for this purpose.
Reconnect the fuel hose and cables and refit all the body panels.
Finally I lay the bike down on the LHS cylinder just to make sure that I don't have any leaks.
Hope this helps someone...
First thing to do is remove the pump unit from the left side of the tank. You will need a tool to undo the clamp ring, I made one (see the last picture below). Carefully remove the whole pump unit from the tank, if you have a mechanical float style fuel gauge like my '05 GS be careful you don't bend it on the way out (or in).
With the whole unit on the bench, unplug the power connector and then unclip the three rubber mounts as shown in this (unfocused) picture.
Next remove the hose clamp on the pump, I used a (cheap copy) of a dremel to do this.
Heat the hose and remove it (it was very cold the day I did it).
To remove the pump from the housing you will need to remove one of those push on star washer things that holds the pickup filter screen. Prising it off would likely break something so I used the dremel again to grind off the top of the post on the end of the pump. You also need to remove some of the plastic of the pickup filter to get to the post.
After removal of the pickup filter screen.
The pump should now just push out the top of the holder if you pull back the two plastic clips.
Here are pictures of the old and new pumps.
As you can see the replacement pump is a good copy of the original VDO pump.
Next push the new pump into the holder and align it before fitting the pickup filter screen. This just pushes on and then you press on the new star washer clip thing. I found a very small socket and used that and a small hammer to tap it onto the post on the end of the pump.
Put the hose back on and secure with a hose clip, clip the pump unit back on to the holder with the three rubber mounts and plug in the power again.
Now you are ready to install the pump unit back into the tank. As I have found out this can be a bit tricky if you don't get the seal done right. It is quite easy to crimp it and end up with a leaking tank. Very embarrassing at the service station when you fill up, trust me :-(
I grease the inside of the filter seal with vaseline to make it easier to get the pump in without dislodging the seal.
The next photo is of the seal in place ready to install the pump. Note the fuel return hose visible at the top of the hole. This is the hose from the sucking pump on the RHS of the tank. (yes, the tank was rather full when I did this repair).
Then after inserting the pump unit I check very carefully around the edge to make sure it hasn't pushed the filter into the tank. You need a mirror to see all the way around.
Now fit the ring and torque down to 35nm. This picture shows the "special tool" I made for this purpose.
Reconnect the fuel hose and cables and refit all the body panels.
Finally I lay the bike down on the LHS cylinder just to make sure that I don't have any leaks.
Hope this helps someone...
