Midnite's Fuel Pump Transplant Surgery

Ok, not sure if you've read any of my other posts about what happened to my fuel pump. Well,,, I just hooked up my FMF Powerbomb, Q4 and EFI Programmer. As I was going to attach the connectors under my fuel tank, I did something idiotic..... I dropped my tank! Snapping the little, plastic fuel line connecting elbow that is attached to the fuel pump. Ok, let me back up. The reason I dropped it was because my WIFE made me! I have my bike in my basement so I can do some mods and as soon as I unscrewed my tank, and had it teetering on it's side on the bike frame, my wife called! I held the tank with one hand while holding the phone with the other. I told her I was in the middle of something important but all she kept saying was "what do we need at the supermarket?" And "are you sure we don't need anything? How bout milk? How bout bread?" Meanwhile my frustration got the best of me and the tank slipped from my grip and broke the connector as it fell to the floor (or maybe it broke when it hit the floor). After swearing and eventually calming down, I tried to look for the piece that broke online and in my service manual. Nope. Nobody sells the part. I had to buy the entire F$#@ing fuel pump at $312 retail ($192 from Honda Service Center - plus tax and shipping). Well, I came to this forum and posted my dilemma and the great people here steered me in the right direction. I was told if I get somebody's broken pump I can just exchange pieces. Although most people said it would be hard and they probably would just bite the bullet and buy a new pump. WELL, I put a "wanted" post and my new friend Rick (Zestymac) from this forum said he would sell me his. (I guess it was a working pump but off of an 08 and made in the months when a lot of them were faulty). Well, we agreed on a great price and he shipped it the next day and I mailed him a check the same day. Trust is a great thing! Well, the pump came today and I just finished exchangng parts and putting it back in and guess what???? The bike fired right up!!!! I actually pressed the button with one hand while holding a fire extinguisher in the other, because after all, I was STILL in my basement. No fire or explosions so I think I'm good! Below are my step by steps with pictures and BRIEF explanations!

Here's the piece under my tank that broke:


Here's the pump removed;


Here's the inside of the pump. Nothing broken;


I originally thought I would just replace the fuel connector that broke, so I had to cut, saw, dremel, drill and pull the piece out. The connector is made to snap in and not pull out so it was a bitch to get it out;


I used all these tools to do it;


The black fuel line is a hard, plastic, non flexible tubing that is heat shrunk onto the connector, so I had to cut the connector off and carefully drill out what was left of the connector in the tube just in case I wasn't able to replace the tube with another;


Well, I finally got it all out and my used pump arrived. Perfect shape


Meanwhile Rick and I discussed via email that I should just try to use the bottom half of his pump with the top half of mine. So... that was my plan. So I cut his tube;


And tried very carefully to pry the pump apart. Even though it has tabs that snap it together, it was not made to unsnap apart;


But after some oil, muscle and patience, it came apart;


I did the same with my pump, unhooked the wires and snapped Ricks pump with mine. Worked GREAT! I even was able to use the hard plastic fuel line. I heated it up to soften it a little and forced it on the connector and I ziptied it for a little added insurance;


Here it is, all set and ready to go back in;


I threw it back into the tank;


Hooked up the bikes fuel line and electrical connection and checked for leaks;


And I didn't find any! I then, like I said, started it up with fire extinguisher in hand and it started right up!!!!! Hopefully I won't have any problems but I think I'll let it run fpr a while before I actually sit on the bike, seeing that if it DOES explode, I would prefer my crotch wasn't too close to the tank. I want to thank Zestymac again for selling me his pump for cheap and mailing it right out, everybody on this site for offering advice and to you for reading this long winded post!!

Randy (Midnite171)

Looks good.

Neat-o.

Sarah

Happy to help out here, It was a great project undertaken by two total strangers with a common goal.....Build a good thing from two broken things and more importantly not to pay $200 for a new pump because of a broken 89 cent elbow!!!

Maybe you can do a postmortem on my pump motor to see if there is something obvious that caused these early pump failures.

This thread should be cross posted to ADV Rider , Thumper Talk and SMJunkie.

Best, Rick

http://www.cafehusky.com/threads/wanted-your-failed-fuel-pump-assembly.17270/

Happens to Husky's too...