Fuel Pump Fix

First topic message reminder :

After 4 days trying to fix my ruining problems of no power, top speed of 10 kph OR 110 kph and no acceleration. I traced the fault to the fuel pump assembly. Sometimes it would work, other times it wouldn't. Pressure was either good or poor. It looked like a dodgy fuel pump which Suzuki want $700. If i had taken it to a dealer they would have replaced the assembly which would have fixed the problem but cost me $1000.

I'm unemployed at the moment so that was out of the question. I doubt VERY much I'm the only person to have this problem in the past
or future.

Photos and instructions following

$44 for the fuel strainer. I either got the last one in stock at the suppliers or the last one in country? Just looking at the current one, it looks well used. Wonder why they don't have it on the service schedule??

Apparently your new one will look like your old one as soon as fuel torch's it .Though it should filter better.

Great diagnosis Gus - I think you may have just saved me $700. I have had the same problem which I have been chasing for weeks and would have bought a new pump this morning if they had'nt been on backorder!! After changing the fuel strainer twice at $45 a time I was suspecting the pump as well. Did your fix this morning and the bike goes fine at the moment.

The Suzuki workshop manual refers to this plastic housing as a "fuel filter" but never mentions it again and I did look from the top down there with a light for a filter but missed it.

Also the workshop manual has a big warning NOT to ever remove the fuel pressure regulator from this housing but I see from the photos you did and it has'nt seemed to matter to you so I don't know what their problem is. Can I also say that I found a piece of welding wire with a small 90 degree bend at the bottom, hammered flat like scraper seemed to clean the crud sucessfully.

I can't believe we are the only two to have had this problem and I can't find it mentioned elsewhere but I hope your fix saves others buying a new pump for nothing.

Once again - much appreciated!!!! With skills like that I hope you are not unemployed for long.

If you take that plastic housing off the aluminum tube (just pressed on ,sealed with o-ring ) you can see the filter from underneath .Thing is it
looks pristine from that side .Keep us posted i'd be wrapped if it works.

I didnt see the dont remove part . Replace the 2 small o-rings to be on the safe side 20c each from a bearing shop.Pump from wreckers
was $250 ,i priced it .Scary thing is it wont fix the problem if you only get the pump.

There is no way we are the only two. What a great money earner for the dealer .$700 for a filter clean.

What mileage do you have on your Bandit ? Mine 37.000 kls

When I first looked at the plastic housing I had'nt removed it from the tank unit so I was only looking in from the top. It was'nt till I saw your solution I pulled it right apart and saw the filter from the bottom. As you say, just a pump will not fix this problem but I understand the "pump" from Suzuki is the complete tank unit - they don't sell just the pump.

My Bandit is a 2007 with 36,000K - I will let you know how it goes in the future.

Thats interesting .I just went and checked my mileage .36,475 kls and i have done about 4oo kls since the problem "fix".
Same distance . Mmmmmm

Hey Gus _ Put about 350Ks on the bike today and it's running like new!!!!

Thats great .I kind of forgot what it should run like .Now its back to " this thing moves ".

Hi Gus, my brother has a DL650 that had a bad noise coming from his fuel pump, I told him to check out your thread. Although not same he said that your thread was great and hepled him sort out his problem, I am passing on his thanks to you for all your hard work, he said it was bloody great and thankyou very much!! By the way when the next scones ride?

Phill

Good question .I have to go to hospital in 10 days for a small op, but will be out of action for a few weeks after that .

Hi guys. Bandit is now fixed and going like a bullet thanks to gus's fuel filter fix and the FI Tuner Pro. I pulled out the pump and checked the filter in the bypass. It's not a small filter in the hole but a mesh wall that divides one side from the other. After a lot of flushing and blowing out, I finally got it clean. The main pick-up filter was also black with crap. Now that it has clean fuel and a mapped exhaust it's put a smile so big on my face that I gotta watch out for bugs! Thanks to Gus and all of you. Stay safe.

If (when) it happens to mine I'm going to send Gus $100 because I reckon that is a cheap fix.

Just tell me truthfully ( i know you know ) if Aliens exist .

More than happy the "fix " works for people .That makes the 5 days working on it worthwhile .Actually i hanvt change that tea-bag
fuel filter .

Just checkin back in Gus - have done about 2K now after performing your fix and have not had any sign of a problem. Thanks again!!!

So is EVERYBODY"S Bandit slowly getting slower ? It must be a a slow build up of "crap ". Should it be cleaned every 10,000 kls .and therefore be
added to REGULAR MAINTENANCE ?

I know this doesn't quite relate to the bandit but the info on this thread could have a few ideas on how to improve things.

Haven't had a chance to compare apples with oranges yet so might not be anything either.

Not 100% sure if you need to register to see this thread, but I don't think so as I was looking at it without logging on.

dhula wrote:I know this doesn't quite relate to the bandit but the info on this thread could have a few ideas on how to improve things.

Haven't had a chance to compare apples with oranges yet so might not be anything either.

Not 100% sure if you need to register to see this thread, but I don't think so as I was looking at it without logging on.

That was interesting, I liked the way they have a measurement of the fuel flow for a good bike, it would be good if someone could measure the amount pumped in a minute by a good bike as a base line. Sorry can't help, no fuel pump.

I've had the same problem and the same answer Gus buy a new fuel pump. Thanks Gus after my coffee I'm going to fix that pump.I would like to shout you a beer or two. Cheers Chris
The Mancave in Margate on MacDonnell Rd

Don't muck around fixing it - just buy a new pump - you know that Suzuki and the dealer needs the money.

Let us know if it works ahh Turd.

I know this is going to sound self indulgent but this fuel pump fix seems to work . With so many new members over time its (the thread ) is slowly
going to slide down the chart and be lost to them .Non members will just not see it that far back . Would it be a good idea to make it a "sticky" ,is that how you say it ?

gus wrote:I know this is going to sound self indulgent but this fuel pump fix seems to work . With so many new members over time its (the thread ) is slowly
going to slide down the chart and be lost to them .Non members will just not see it that far back . Would it be a good idea to make it a "sticky" ,is that how you say it ?

Good call Gus. I agree. Send a PM to Cam mate in case he doesn't log on for a while.

I have just left for a trip to tassie on bandit. Got about 200 kms into trip & bike started coughing & farting & could only get 80kph out the bitch!! So stopped at Pt Augusta pulled tank off and removed filter then tank back on. Bike went well for about 50kms then coughing again so last 250kms to adelaide at 70kph what a effin pain in the ass no new pumps in OZ 3 week wait. Got passed by boats caravans & even combi vans how humiliating. had to cancel tassie ferry booking accomodation etc. This has turned into trip from hell. Things had better go better next time or suzuki Oz will be getting a rocket up their u no what.javascript:javascript:emoticonp('')emoticonp('')

Mine was like that. I pulled it apart and looked at the screen Gus mentions and it was OK, so I re-assembled the fuel pump assy and blew everything out with compressed air along the way. Put it back together and it was a lot better but still not right. So I ordered a new filter ($45) and pulled it out again and re-installed a with the new filter. Now great, back to normal, it ran through 200 with nary a sign of letting up. I didn't expect it was the filter 'cos the bike has only 11500 kms, seems much too soon, but there you go, maybe I picked up a bad load sometime.

On a 5 day tour with mulitple bikes and the trusty 1250SA Bandit couldn't keep up - very unusual. Gradual power loss over 2 days ended in a slow crawl into Grafton being overtaken by caravan's (how embarrassment). Great temporary repair from the brilliant folk at Grafton Motorcycles - thanks Darryl, (blocked fuel filter) but unfortunately, the next day, the flat patches during acceleration told me it still wasn't quite right. It just lacked the zing I was so familiar with. Handed it over to a dealer in Sydney, and it now needs a new fuel pump. About $800 all up to replace and fit, but a bit beyond my limited technical expertise to have a go myself.

The strainer was dirty too, but the tank was clean, so must have been a dirty fuel load from somewhere. I was advised by the service guy that there might be too much additive in 98 fuel because he sees this problem a lot with people who use it religiously (like me, based on previous advice).

I felt like I was nursing my wounded steed home. Will be pleased to have it zinging again.