ATVs and motorcycles can be an exciting and convenient form of transportation, but the fun soon ends when motorcycle fuel pumps need replacing.
Fuel pump repair and replacement is very important. If an engine lacks a functional fuel pump, that engine will “starve” and immediately stop running. It’s also critical to install motorcycle fuel pumps in the correct way since if it’s done wrong, the entire system can be damaged.
However, with the following instructions, you’ll be well on your way to understanding how to replace motorcycle fuel pumps.
Step 1: Preparation
Before you begin disassembling motorcycle fuel pumps, you must make sure you have the following tools:
- Fire extinguisher
- Replacement fuel pump
- Open-end wrenches
- A new fuel line
- Socket set
- Phillips-head screwdriver
- Regular screwdriver
- A large fuel catch container
Step 2: Make Sure You’re Safe
Anytime you’re working on a project yourself, it’s important that your personal safety be your highest priority.
Replacing motorcycle fuel pumps should always be done in an open area, or at least an area with plenty of ventilation and room to work. Also, be sure and keep the fire extinguisher within reach, just in case.
Step 3: Check Fuel Pressure
In order to supply adequate fuel injection to the engine, an electric fuel pump must emit a high fuel pressure. The fuel is highly pressurized, and this produces power.
It’s important to realize that, just because you turned the engine off, the pressure in the fuel pump hasn’t disappeared—at least, not instantly. Before you remove the fuel pump, the pressure must be released.
To relieve fuel pump pressure, first turn the engine off, then locate the fuse for the fuel pump and then pull that fuse out. This will eliminate the pressure within the engine’s fuel system.
Step 4: Disconnect the Negative Terminal
Before you can take out the fuel pump, you must disconnect the negative terminal from the engine’s battery. Otherwise, removing the pump system by itself can cause the engine to produce sparks flying in all directions. Sparks can cause fires, which would mean serious danger to both you and your motorcycle.
Step 5: Remove the Fuel Pump
Usually, the fuel pump will be located inside the fuel tank. Once you find the pump, unbolt or unfasten it, and pull it out, slowly. Double-check to ensure that every component is disconnected as you pull it away.
Step 6: Replace the Fuel Pump
Perform the following instructions to replace the fuel pump:
- Disconnect all fuel lines.
- Ideally, you will have someone standing by and ready to block the fuel lines for you. Otherwise, gas will leak out of them as soon as they’re disconnected.
- Put the new fuel pump in, and reconnect the fuel lines.
- Bolt or fasten down the fuel pump.
- Start the engine to determine whether the installation was a success. Check for any leaks.
And there you have it—the basics of what you need to know to replace motorcycle fuel pumps. Hopefully, this article has proven helpful to you as you work on your motorcycle or ATV.