How To Rebuild Motorcycle Fuel Pump | 2003-2004 Suzuki SV650/SV1000

How to rebuild a motorcycle fuel pump on a 2003-2004 Suzuki SV650/1000. 2005 and up models are similar. Complete tutorial on how to rebuild the pump as well as how to remove and reinstall the gas tank.
Quantum Fuel Systems Rebuild Kit I Used:
www.highflowfuel.com/qfs-fuel...
2003-2004 OEM Parts From Suzuki:
www.babbittsonline.com/oempar...
2005-2009 OEM parts From Suzuki:
www.babbittsonline.com/oempar...
00:00 Introduction
00:21 Removing Fuel Tank
02:37 Disassembling Fuel Pump
14:19 Unboxing New Parts
16:00 Assembling Fuel Pump
25:41 Installing Fuel Tank
26:30 Check For Leaks
27:16 Start-Up
27:54 The End
DISCLAIMER:
Due to factors beyond the control of Nick Buchanan Racing, I cannot guarantee against improper use of this information. Nick Buchanan Racing assumes no liability for any property damage, injury, or death incurred as a result of the information in this video. Use the information in this video at your own risk. Nick Buchanan Racing makes no guarantee of any particular result that can be achieved using the information in this video. Nick Buchanan Racing recommends taking all necessary safety precautions when working on motorcycles, working with tools, and operating motorcycles. Nick Buchanan Racing recommends following all manufacturers recommendations and local laws. Any damages, personal injury,
or death, as the result of the information contained in this video is the sole responsibility or the user, and not of Nick Buchanan Racing. I am not an expert technician or qualified instructor of any kind. This video is for entertainment purposes only.

[@colinhart4755]

Great video with great detail, doing mine tomorrow, much appreciated.

[@carleighclaffey669]

Great video! Just replaced my husbands sv650 fuel pump thanks to you!

[@nickbuchananracing]

Awesome. Glad it helped you get the job done!

[@laryan2]

Thanks for the step by step instructions, got my bike up in running in no time.

[@nickbuchananracing]

Youre welcome. Glad to help you get her fixed up

[@MichaelMuller-ok9uu]

Vielen Dank, thanks from Germany, best Video ever 👍🏻💪🏻

[@nickbuchananracing]

Youre welcome. 🤙

[@user-jc1id2kb3e]

Best video I have seen by far. I recently rescued a 2003 SV1000 with no idea what I was doing. I have not taken the pump apart. Low mileage and the fuel system apparently avoided the abuse the rest of the bike suffered. But, I am just now finishing up a 2004 GSXR750 basket case rescue. I opened up the throttle a little yesterday, first test ride, and power started falling off around 6k rpm. Most likely tank crud. Going in as soon as it warms up a little. Thank you.

[@nickbuchananracing]

Thanks! Yeah decent chance your gsxr has poor fuel flow. If its clogged, after you sort things out check the specs for a fuel flow test and give it a flow test before you reconnect the fuel hose. Usually it will give a volume of fuel for a given time. That way you can be sure its good before you take it out for test ride.

[@greggory448]

Nicely made videos

[@nickbuchananracing]

Thanks!

[@lucasbillington2604]

Just ordered one this video is exactly what I needed to do the job without ballsing it up thank you ❤

[@nickbuchananracing]

Youre welcome! Happy to help👍

[@tump1966able]

Thank you for the The help of putting that pump in thank you

[@nickbuchananracing]

Youre welcome.

[@DylonND]

Nick great video! I literally just had mine cleaned, you wouldn't believe how bad it was and somehow monstered through two trackdays. Only thing I had was some lugging and high rpms.

[@nickbuchananracing]

Thanks. Good thing you figured it out. I had a similar problem took me a minute to track down the issue. Had an old gsxr that was carbed but still used a fuel pump, had the same issue, turned out to be when the fuel tank was lowered the fuel hose feeding the carbs was kinking.

[@DylonND]

@@nickbuchananracing so after cleaning it's still having issues so here I go! Using your video as a tutorial :D thanks nick - your tutorials are the best.

[@mathi141]

dont forget to put your heat shield back :P great video about the replace my fuel pump now

[@nickbuchananracing]

Lol, ive been caught.

[@stefipower]

great video! you should become the president of USA sir! 👌

[@painterspaintll]

That's the same set up for a 2005 GSXR.600

[@hukebein92]

The worst is that the high pressure filter is integrated into the pump , if that gets clogged then only thing you can do is cleaning ( I was successful doing it 😏) if still not running good then all the unit needs replacement, the original pump unit is more then 600 EU

[@L_Inks]

Read mixed reviews on the pressure regulator did you have any issues with it while riding

[@nickbuchananracing]

No issues so far. Used these kits on two of my sv650s. One ive had for a year now and no probelms

[@donderk6969]

Hey Nick, awesome video. I have a question. I have a 2003 GSX-R 600 with only 2500 miles on it, but it hasn't been started in about 10 years. When I stored it 10 years ago, I drained the gas, but unfortunately I don't think I got all the gas out. I'm trying to get the bike started now, but the fuel pump was bad, apparently from sitting, so I replaced it, and the bike will not start. What do you suggest would be the next step. I really appreciate any help. Thank you.

[@nickbuchananracing]

Start with the basics of spark and fuel. Check for spark by pulling each plug and grounding it, then press the starter to see if you have spark. Depending on if you do or dont check for fuel coming out of the pump when its being primed. If you have spark and fuel, but it still wont start, the next list of things to check is a but much for me to explain in the comments. But start there and let me know what u find

[@donderk6969]

Thank you so much. Just picked up new plugs.

[@greenbutt6149]

So i just replaced the fuel pump on my 03sv650, same brand and pump in this video. All the connections are set up correctly, but the pump is still not priming/turning on. Fuse is good, I head the relay click when i turn the key but not noise from pump? Any ideas??

[@nickbuchananracing]

Yea use a multi meter and test for voltage at the wiring connector to the fuel pump. Probe the 12v power wire and probe the ground wire. With the key on and the kill switch in the run position you should read 12 volts. Make sure to use the ground pin on the connector and dont just ground the multimeter probe to the battery/ chassis. You need to test for ground at the connector in case thats an issue. If you get power, your pump side of things is the issue. If you have no power coming to the fuel pump connection, you have a different issue.

[@nickbuchananracing]

Also make sure its in neutral. I think these bikes beed neutral even to prime the pump if i remember correctly but i could be mistaken

[@trenthelms]

After disassembly, If I apply 12 volts directly to the fuel pump from a good battery, and it doesn't run, is the pump dead with no option to fix it? I'm coming to that conclusion with a Honda fuel pump and would appreciate your thoughts on this test. I had a lot of gunk in the tank. I'm wondering exactly what makes a fuel pump fail.

[@nickbuchananracing]

Idk exactly what fails inside but if you apply 12.6 volts and it doesnt spin. Consider it dead. Im guessing they fail from seize up or too much corrosion in the windings maybe 🧐

[@trenthelms]

@@nickbuchananracing Thank you, Nick! This helps and I have ordered a QFS kit thanks to your walkthrough and feedback to others and me. Great video. Thanks for your time and instruction.

[@nickbuchananracing]

@@trenthelms youre welcome

[@brocksamson2704]

what is the purpose of the 2 hoses at th-cam.com/video/AzMUd7wveTo/w-d-xo.html. are those vacuum hose

[@nickbuchananracing]

So those are a vent hose and a drain hose. If you look underneath of a gas cap assembly(the part you need to unscrew to take off, not just the gas cap) on most bikes you will find two holes. One hole is just a drain hole that has a tube that travels through the inside of the fuel tank and to the outlet on the bottom of the gas tank. It will drain water from rain or washing your bike, or extra fuel if you acidently overflow or spill gas when filling up. The other hole is a vent hole. When your fuel level drops in the tank throughout your ride, the volume of air in the tank increases. You need to have a path to add more air to vent the tank to compensate for less fuel and more air is your fuel levep reduces. Thats the second hose. Its a vent line, it has another tube that travels through the gas tank and up through a tiny hole under the gas cap base, and joins another hole that travels through the fuel cap to make a path for air to vent your tank. This vent tube also works in the reverse direction, as in not just venting air into your tank as the fuel level lowers, but also venting excess pressure from expanding fuel, to the outlet of the vent tube, to relieve the pressure. Youll notice this when you park your bike in the sun on a hot day, you might hear some fuel hissing out the vent hose.

[@brocksamson2704]

i bought a used bike and i only have 1 hose on there. is it crucial that both hoses are on there. where would the other end of the hoses go, because the one there looks like it is just hanging freely right around the oil radiator.@@nickbuchananracing

[@ordinarytwat69]

What should I use to lube the gaskets

[@nickbuchananracing]

Gasoline or kerosene seemed like a good idea to me. I used kerosene

[@ordinarytwat69]

@@nickbuchananracing thank you