Retrofitting an 08+ fuel pump - Kawasaki ZX-10R.net
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post #1 of 17 Old 04-10-2010, 06:48 AM Thread Starter
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Retrofitting an 08+ fuel pump

In case anyone is interested, tonight I fitted up an '08 fuel pump to my '07. The reason for this was that I'd read that the 08 model included a 'flat' type fuel pump to allow a larger airbox ; sounds to me like it's smaller, so I suspected it would be significantly lighter. On the basis that the '08 makes at least as much power as the '06-'07 (and therefore unless it is a lot more efficient, would require the same amount of fuel to be delivered), it seemed likely that there wouldn't be any fuel supply problems.

Big thanks to MagicMavis for sourcing me a new fuel line, at a much better price than locally or even e-bay (where apparently postage is insanely expensive even for small items ...).

I fitted it up tonight, noting as I did the following weights :

07 pump 997g fuel line 33g total 1.030 kg
08 pump 686g fuel line 30g total 716g

to give a saving of 314g, around 2/3 of a pound for Americans and other non-metric users.

Only issue thus far, it appears that the angle of the pump outlet is forcing the line firmly against the airbox - will be checking it closely tomorrow to make sure it's not being compressed unduly. Also need to confirm that the line hasn't been kinked anywhere - compare the assemblies in the pic attached to see the different bends to the lines.

Will fire up the bike tomorrow (once I collect my Lithium Ion battery ), and will report back.

Cheers,
Brian
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post #2 of 17 Old 04-11-2010, 02:36 AM
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If your very carefull, you can cut the plastic fuel lines off the pushlock fittings (use razorblade and cut with the length of the fitting a little at a time until you seperate the plastic hose) then you can put standard rubber fuel lines on them with a small hose clamp. This'll give you alot more flexability and will only cost about $2 in hose and clamps.
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post #3 of 17 Old 04-11-2010, 05:16 AM Thread Starter
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Thanks for the tip, but I'm thinking I'd prefer to stick with OEM given these are pressurised fuel lines :) Better safe than sorry !

Fired up the bike tonight, it seemed to idle Ok ; since it's no longer road-legal and I live in a quiet neighbourhood, it'll be a while before I take it to the track and see how it runs on top. According to the manual specs, 08 pump runs 1 psi less pressure (43 vs 44 psi, 2.3% so not likely overly significant), but flow rate is significantly lower (67 ml vs 72ml over a 4s period, 6.9% down). Whilst the worshop manuals don't give any benchmarks as to what is acceptable (they talk about being 'much higher' or 'much lower'), I'm a little nervous that the reduced fuel flow of the later pump may lead to a high speed lean out ; this is perhaps something I need to check on a dyno.

Cheers,
Brian
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post #4 of 17 Old 04-25-2011, 12:14 AM Thread Starter
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Just realised I never followed this up with a track report.

I've yet to get round to putting it on a dyno, but the bike runs perfectly and goes like a dog shot in the bum. I'm very happy with the mod, and would recommend it to anyone looking for a relatively cheap bit of weight reduction.

Cheers,
Brian
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post #5 of 17 Old 11-19-2015, 05:01 AM Thread Starter
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Just spotted this old post of mine. Prior to fitiing a kit head gasket, with full Akrapovic system, BMC race filter, kit ecu (standard map) and secondary butterflies removed, it dynoed at 175.5 rwhp with a very smooth power curve, so no fuel delivery problems.

Cheers,
Brian
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post #6 of 17 Old 11-19-2015, 10:19 AM
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Originally Posted by greenman43 View Post
Just spotted this old post of mine. Prior to fitiing a kit head gasket, with full Akrapovic system, BMC race filter, kit ecu (standard map) and secondary butterflies removed, it dynoed at 175.5 rwhp with a very smooth power curve, so no fuel delivery problems.

Cheers,
Brian
great thread revival and result.

BD



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post #7 of 17 Old 11-19-2015, 11:11 AM
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I wish 2011 's pump weights 400gr. . . LOLOL
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post #8 of 17 Old 11-22-2015, 05:49 AM Thread Starter
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great thread revival and result.

BD
Thanks BD.
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post #9 of 17 Old 11-22-2015, 05:50 AM Thread Starter
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I wish 2011 's pump weights 400gr. . . LOLOL
I don''t know anything at all about 11+ bikes, but you can't retrofit an earlier pump ?

Cheers,
Brian
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post #10 of 17 Old 12-06-2015, 04:45 AM
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Quote:
Originally Posted by greenman43 View Post
I don''t know anything at all about 11+ bikes, but you can't retrofit an earlier pump ?

Cheers,
Brian
I think the 2011+ ZX10s have a square bottom flange instead of a round one.

The difference in the 08 pump assembly is that the pump motor is very small.


Great thread and weight savings as always by greenman.
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