**Caution** Fuel Pumps - Kawasaki ZX-10R.net
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post #1 of 25 Old 12-10-2008, 12:06 AM Thread Starter
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Exclamation **Caution** Fuel Pumps

For those with Aftermarket Fuel Pumps or Pumps that have been removed....

I have a Walbro fuel pump in my bike. While riding this past weekend the bike shut down all of a sudden. It never cranked back up. I got back home and took things apart and found the problem.

There is a white plastic clip that connects the metal pump to the black housing. As the fuel pushes through the black housing it is sent through the tank interface and out the fuel line. I noticed that the black housing was seperated from the pump by a rubber boot. Well the pump and boot was seperated from the black housing. After taking everything apart the white plastic clip loops were broken therefore not keeping the assembly together. This could be due to stress induced from taking the assembly apart and this could also be due to the higher fuel pressure that the aftermarket fuel pump produces. I'm going to try to get a metal clip fabricated to eliminate this problem for good because you can only buy the entire pump/interface assembly from Kawasaki.

I know this might be somewhat confusing to those who haven't had this apart. I took pictures and can post them if anyone is interested in this problem. I just wanted to give a heads-up to everyone out there.

-Derrick

"Besides, my ZX-10R eats GSX-Rs for breakfast." -- SportRider Magazine Article
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post #2 of 25 Old 12-10-2008, 12:42 AM
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cool ... my pump has been whinging at me for ages, and is just getting worse


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post #3 of 25 Old 12-10-2008, 02:23 AM
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Quote:
Originally Posted by axo250 View Post
For those with Aftermarket Fuel Pumps or Pumps that have been removed....

I have a Walbro fuel pump in my bike. While riding this past weekend the bike shut down all of a sudden. It never cranked back up. I got back home and took things apart and found the problem.

There is a white plastic clip that connects the metal pump to the black housing. As the fuel pushes through the black housing it is sent through the tank interface and out the fuel line. I noticed that the black housing was seperated from the pump by a rubber boot. Well the pump and boot was seperated from the black housing. After taking everything apart the white plastic clip loops were broken therefore not keeping the assembly together. This could be due to stress induced from taking the assembly apart and this could also be due to the higher fuel pressure that the aftermarket fuel pump produces. I'm going to try to get a metal clip fabricated to eliminate this problem for good because you can only buy the entire pump/interface assembly from Kawasaki.

I know this might be somewhat confusing to those who haven't had this apart. I took pictures and can post them if anyone is interested in this problem. I just wanted to give a heads-up to everyone out there.

-Derrick


you can search my posts, same thing happen to me.

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post #4 of 25 Old 12-10-2008, 09:16 AM
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glad ya found it, get her fixed so we can duke out the 2mm vs 3mm lol
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post #5 of 25 Old 12-10-2008, 10:01 AM
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Dont have one in my bike, but the same thing happened in my car a while ago. I believe that there was a separate kit that helps with this, or at least the shop charged me for a kit, which fixed it, knock on wood.
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post #6 of 25 Old 12-10-2008, 11:49 AM
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Happened to me twice. Luckily I was close to home. If you make that clip I'll buy one off you!

04 Pearl Blazing Orange ZX-10R
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post #7 of 25 Old 12-10-2008, 12:53 PM
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post up those pics

bike is down for not but not out
turbo project is a slow go no money

Need some work done
call 586-214-2414
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post #8 of 25 Old 12-10-2008, 04:02 PM Thread Starter
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The first pic gives you a good overall.
The second shows the way the pump and black housing should be.
The third is how I found it.
The fourth shows the plastic piece up close and how I feel about it.

I went to one machine shop and they told me 75-100 bucks to make one. I'm going to try one of the guys at work to see if he'll make one out of scrap left over from shuttle stuff.
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"Besides, my ZX-10R eats GSX-Rs for breakfast." -- SportRider Magazine Article

Last edited by axo250; 12-10-2008 at 04:04 PM.
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post #9 of 25 Old 12-10-2008, 05:20 PM
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what about some heafty zip ties.....
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post #10 of 25 Old 12-21-2008, 11:17 PM
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how long have you had the pump? I've had my Walbro for over a year and no problems. The only problem I had was the first day because of some stupid o-ring came off from the stock pump, so when I was putting in the Walbro it didn't allow it to go completely in to the black housing and didn't let the fuel flow through so kept belowing the fuse.

Did you shave down the rubber piece on the buttom and the white v shaped spacer?

Does everyone here with this problem have a walbro?
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