Gen 2: 2006-2007 How to install new fuel pump? - Kawasaki ZX-10R.net
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post #1 of 19 Old 06-08-2011, 06:49 PM Thread Starter
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How to install new fuel pump?

My fuel pump just went out couple weeks ago and it was kind of a bitch to remove from the tank! I just ordered a new one an was wondering if there was a special way to put the new one in without forcing it an possibly damaging it?

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post #2 of 19 Old 06-08-2011, 10:45 PM
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I never had to do it yet. The PDF manual is no help?

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post #3 of 19 Old 06-09-2011, 01:19 AM Thread Starter
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I have the book manual and it doesn't really say?



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Originally Posted by neverendingmods View Post
I never had to do it yet. The PDF manual is no help?

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post #4 of 19 Old 06-09-2011, 06:28 AM
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Easy job, although your tank needs to be virtually empty.
  1. Remove LH side cover
  2. Unplug electrical socket that leads to the pump
  3. Remove RH side cover
  4. Remove seat
  5. Remove steering damper
  6. Lift tank up, and support it so you can get access to the fuel hose
  7. Undo hose from pump end (refer to manual for this part)
  8. Unplug hose from pump body
  9. Remove support, lower tank back into place
  10. Undo rear mount bolts
  11. Remove tank, and flip over
  12. Undo the 5 (?) bolts and carefully withdraw the fuel pump
Installation is simply the reverse.

Cheers,
Brian


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post #5 of 19 Old 06-09-2011, 06:32 AM
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Sorry, just re-read your question and realised I didn't really answer it ... No, there's nothing difficult about putting it back in, just make sure that the outlet is correctly oriented to the fuel hose.

Apologies,
Brian


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post #6 of 19 Old 06-09-2011, 09:54 AM Thread Starter
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Yea but is there a special way to put it in there without damagin it? It's a really tight fit! And when I took the told one out I basically had to almost rip it out. I was just hopin I could put the new one back in without forcing it an risk damaging it? I just thought maybe there was a special way or technique to take it out or put it in that I didn't know about?




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Originally Posted by greenman43 View Post
Sorry, just re-read your question and realised I didn't really answer it ... No, there's nothing difficult about putting it back in, just make sure that the outlet is correctly oriented to the fuel hose.

Apologies,
Brian

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post #7 of 19 Old 06-09-2011, 10:29 AM
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Zig, it's a lil bit of a tight fit but i just twist it around...i couldn't find any special way and I've removed mine about 4 or 5 times. no damage to it at all. To be honest I just shove it in there no delicate touches. you'll be fine don't worry about it.

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post #8 of 19 Old 06-10-2011, 11:22 AM Thread Starter
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The new one went in surprisingly smooth! No issues! Did your's go bad on you too, that you had to remove it that many times?





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Zig, it's a lil bit of a tight fit but i just twist it around...i couldn't find any special way and I've removed mine about 4 or 5 times. no damage to it at all. To be honest I just shove it in there no delicate touches. you'll be fine don't worry about it.

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post #9 of 19 Old 06-10-2011, 02:49 PM
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https://www.zx-10r.net/forum/showthread.php?t=77799

Take a look at that thread for the first two times I had to take it out. Then just a month ago I bought a new/old tank.

Trust me man it will be fine.

Florida has a poor job market! :headshake
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post #10 of 19 Old 06-10-2011, 08:07 PM
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I just got done swapping mine out also...and was wondering the same thing about taking it out. Glad to know it wasnt just me...lol. New one went in without any issues.

Damian...aka Big D.

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