Aftermarket fuel pump - used on 3rd gen

Fuel pump seized up on the 3rd gen. Checker Auto had a 2-3psi 28gph 12v pump on the shelf for $44. Size is virtually the same as the OEM pump.

I also spent $20 in brass fittings from the "bend your ass over" hardware store.





OEM installation (pump relay removed during troubleshooting)




The mount flange for the new pump tucked nicely in between the battery box/inner fender and the frame. I had to break off the frame tab for the side stand switch connector. (Green connector above the fuel pump in the photo above). The brass pipe redirecting the fuel inlet interfered with the little tab. I also cut the electrical connector off the old pump - soldered and shrink tube.



Put over 100miles on it today and it's working great. Fixed for about $65.

 

Since the bike came with a pump, it won't run when the pump shits-the-bed. The bike ran fine and the next day I went to start it up, it ran like shit for a few minutes until it wouldn't run at all (burned off the last of the fuel in the float bowls).

I pulled off a fuel line to see if it was getting gas - it wasn't. Followed the troubleshooting guide in the factory service manual on how to test the fuel pump relay and narrowed it down to the pump being bad.

 

Same. The pump relay is controlled by the ECU (on the 3rd gen anyway). When the motor cranks, the ECU sends power to the relay, closes the contacts and fires the pump. When I shut off the motor with the kill switch, the pump remains on - unlike the OEM pump and I haven't figured out if the current draw won't allow the relay to unlatch or what's going on.

The 2psi pressure of the pump shouldn't overcome the float needles. Shouldn't being the key word. I have flooded my motor by leaving the key on so the radiator fan could continue to run on a hot day. I have not replaced the float needles on this bike.

The OEM pump has a switch on the back of the pump under that black cover. I think it's a pressure switch that shuts off the pump when it reaches pressure.

 

Have used mine for several hundred miles with the only problem being flooding after the engine is off and key left on.

There's always the "going up in a ball of flames" after a crash issue, but I'm unsure if the OEM pump shut off when the bike tips over either as there wouldn't be any pressure in the line to kick the switch on the back of the pump.