Fuel Pump Fix

gus wrote:Thanks guys, I better keep working. The actually small pump can easily be tested by putting it in a bucket of fuel. Extend the wires a couple of feet to a battery, blue wire positive black wire earth (its marked). It will "jump" a little when connected and then be smooth, flow should be strong.

Reassemble everything, put it back into the bucket and retest. With mine flow (assembled) was good sometimes and poor the next time making it look like a faulty pump. The pump on its own  ALWAYS had good flow. Ever thing in the assembly is basic, no springs, no ball bearings nothing there to confuse any one. The pressure reg. can be tested with a home compressor. Air should pass through it at 45 + psi (not less) use a pointy nozzle and watch com pressure gauge.

Looking at the hidden mesh screen(you can just see it from underneath) IT LOOKED LIKE NEW, SHINNY NO DIRT, BUT IT WAS LIKE IT HAD A
CLEAR VARNISH ON IT. ONLY NOTICEABLE WHEN YOU SCRATCHED IT WITH THE COPPER WIRE.

All the pump assembly parts below

Below. This part of the assembly where i am pointing is where the pump fits into.
Underneath that little hole is a mesh screen (believe me) insert a stripped end (copper) Of wire and use like a toothbrush. 
Insert wire from other side and repeat. You will feel the mesh screen


You will see gunk appearing. Wash out with boiling water. Repeat and repeat again.

Reassemble after cleaning and checking every thing else.
In the last 4 days i could only get 15 kms. Today i did 130 and it ran like a charm. Now i wonder how many good pumps have been chuck away worth $700. It might not work for you, but it has got to be worth a try before you give it to the dealer. They will say you need a new pump for sure.

Chancho196 wrote:


 I hope this isn't considered spam

Chook wrote:

Chancho196 wrote:


 I hope this isn't considered spam

Not at all, great first post with good info.

Welcome aboard, what part of Oz are you from Chancho?

GSX1100G wrote:Hi LJ,
3 cheers for Gus!,
Tea bags are cheap , "Gus"s fuel filter fix" is definitely worth doing. should be able to hit 120 in 2nd easy now.
might as well do air filter while your in there .
don't know about cost for valves, but no doubt they will replace about $100 worth of gaskets to ensure no oil leaks.
the fix you just did won't be done in a shop - sell you complete regulator $170 plus labour, or new complete pump $700 plus labour.  so with all that and the plugs yourself,  you are still in front getting them to do it.

LittleJohnny wrote:That's a great pic! what a sh#t of a place to have a filter! I have noticed my 1250s surging slightly between 3-3500 rpm, decided to pull the tank and have a look at the teabag filter and this awkward little gauze. Used the copper wire toothbrush method to clean the gauze, I used most of a can of carb cleaner in there and a bit of compressed air and a whole heap of black gunk came out! I gave the teabag filter a good 45 minutes in my new Aldi ultrasonic cleaner but alas I fear its too far gone.. There seems to be sludge in there that no amount of carb cleaner and air will get out. I ended up ordering a new one from the local Zook stealer, hopefully it doesn't take til next Christmas to get here... While the tank is off and SuziQ is out of action I decided to yank the plugs and replace them also, by the looks they have never been out and she's done 54,000 odd km. Next project will be to order a set of gauges, and balance the TBs.. Ive made enquiry at the stealership about getting valve clearances done, was "quoted" $400ish and a good day in the workshop, does that sound about right? I could probably tackle it myself but prefer not to....