Motorcycle Fuel Pump Replacement Instructions

Compatibility

This fuel pump is compatible with the following motorcycle models:

• 1999-2012GSX1300R
• 2000-2006 GSXR1000 series
• 2003-2006 AN650 Burgman 650/400

Installation Overview

Replacing your motorcycle's fuel pump is crucial for optimal engine performance and reliability. This guide will help you install the new fuel pump efficiently.

Tools Required

1. Basic Tool Kit

   • Socket set (metric sizes)
   • Ratchet wrench
   • Screwdrivers (flathead and Phillips)

2. Specialty Tools

   • Fuel line disconnect tool (if applicable)
   • Torque wrench (for proper tightening)

3. Safety Equipment

   • Gloves (to protect your hands)
   • Safety goggles (to protect your eyes)

4. Miscellaneous

   • Clean rags (for cleanup)
   • Container for fuel (to catch any spills)

Installation Steps

1. Preparation

   • Ensure the motorcycle is parked on a flat surface and the ignition is turned off.
   • Disconnect the battery (negative terminal first) to prevent any electrical shorts.

2. Remove the Fuel Tank

   • If necessary, remove any panels or covers that obstruct access to the fuel tank.
   • Unscrew the fuel tank mounting bolts and carefully lift the tank off.

3. Disconnect Fuel Lines

   • Use the fuel line disconnect tool to detach the fuel lines carefully, ensuring no fuel spills. Have a container ready to catch any residual fuel.

4. Remove the Old Fuel Pump

   • Unplug any electrical connectors attached to the old fuel pump.
   • Unscrew the mounting screws/bolts holding the fuel pump in place and remove it.

5. Install the New Fuel Pump

   • Position the new fuel pump in place and secure it using the mounting screws/bolts.
   • Reconnect any electrical connectors.

6. Reconnect Fuel Lines

   • Reattach the fuel lines securely to the new pump, ensuring a tight fit to prevent leaks.

7. Reinstall the Fuel Tank

   • Place the fuel tank back on and secure it with the mounting bolts. Reattach any panels or covers that were removed.

8. Reconnect the Battery

   • Reconnect the motorcycle battery, starting with the positive terminal.

9. Test the System

   • Turn on the ignition (but do not start the engine) to allow the fuel pump to prime. Listen for the pump operating without any leaks.
   • Start the motorcycle and check for any fuel leaks around the connections.

Final Notes

Once installation is complete, ensure to clean up any spilled fuel and properly dispose of any old parts. Enjoy improved performance with your new fuel pump!

Customer Support

For any questions or concerns, please contact our customer support team for thorough technical assistance and service. Your satisfaction is our priority!