Dear Norman, Great video as usual. Looking at the fuel pump assembly I want to share my experience on a M50 which is a similar bike. My bike suddenly died one day while riding and wouldn't start while the engine kept cranking. I was lucky to find a mechanic who helped me fix the issue. Nowhere in the service manual was mentioned the fault we discovered. There is a little thermistor attached on a bracket that goes around the actual pump. The soldered connection on the wire had broken due to corrosion which prevented the fuel pump from running and the bike would not start. A new solder solved the issue.
Brother, I have to say thank you once again, I've been watching your videos for the last two months, your explanations and attention to detail allowed me to turn a junked, mistreated M50 into my daily, rebuilt from the bottom up, I greatly appreciate it.
Good evening Norman, First thank you for this completed thoroughly video. I have a 2008 Boulevard C50T that I bought from a gentleman who let the bike sat in his storage shed for 6 years. The gas tank was rusted bad inside. The fuel pump inside the gas tank was badly rusted, and plastic wire cover harness broke into pieces when I pulled it out. So here is a list of things that I have done so far but still couldn't get the bike started: 1) Cleaned the inside tank thoroughly. 2) Removed, cleaned and test the two injectors. I verified that the solenoid on both injectors were working. 3) Put in the brand new fuel pump that I bought on eBay for $170. 4) Installed a brand new battery. After I have everything put back together, pushed the start button, the engine turning but not fired up. I checked the spark plugs and there are sparks on all 4 plugs. I tried to narrow down the problem by trying to spray the starting fluid directly into the upper cylinder valves to see if it started. Yes it did started with the starting fluid until it ran out. So I think the only thing left for me to check is the fuel pump. My question to you is is there a way to manually check to see if this new aftermarket fuel pump from eBay is a good or bad one? Much appreciate it if you can provide me any lead on this. Thanks in advance!
With that rust in the tank you may have some rust in the hose that feeds the tank. The gas line you unhook from the tank has a check valve so you undo the line from the connector and very little gas runs out of the tank. It could have some rust in there. When you first turn the bike on do you hear the pump build up pressure then stop ? The gas system has a pressure system. Something to think about. Norman.
@@danieldyck720 Look in the tank and if there is rust in it, what we did in the old days, Take small gravel and wash it so it is very clean. Put it in the tank and shake it turning the tank as you do this. It will knock the rust loose then flush it out a few times till it's clean. They make a product that you pour in the tank and you turn the tank and it puts a coating in it. Norman.
Thanks again for your videos again. Getting my c50 serviced where I live in Thailand is not really easy. I would have to ship it to Bangkok 400 miles away to get it to a qualified dealer.
Man thank you for that video you save me so much money I watched it about three times and had no problem installing my fuel pump keep putting up videos thanks
Thank you for this. I had my pump go out and this was the only video on the subject. Without it, it would have been quite an ordeal, but with this video, it was pretty straight forward! Thank you!
Hello sir, I have been watching your vidoes and just wanted to say they are great! Thank you for putting so much effort into them to help others!! So I just purchased a 2006 C50 from a friend and it is having a fuel issue I believe. For some reason when he got it from someone else about 6 months ago he drained the tank and then put 87 in it. Since then he says it has ran "funny". So it will start but you have to constantly move the throttle back and forth vigoursly. Then you can get it to move by keep doing the same throttle madness. If you are not fast/hard enough on a constant basis it will die. The bike also has a Fi2000, idle/fuel control thing attached to it?? Never heard of this and will need to research that as well. Do you have any ideas for the issue I mentioned? Any help or guidance would be greatly appreciated! I just purchased this last weekend and I haven't done anything yet. Figured first steps would be check/clean fuel filter, pump, etc etc.
These bike are known to have problems like this. All my research comes up with Take It To The Dealer. I gave up on mine for a while but hope to get back to it sometime. Seems there is no easy fix. Norman.
What is the purpose of the connector inside the tank? I have a 2006 Boulevard C50 and I’m replacing the fuel pump assembly. However, mine does not have that connector. Is it essential?
Hi Joseemc21, I just saw your comment. The 2006 may be different than the 2012. My bike has the fuel pump in the tank so the wire to run it goes down in the tank to get power to the pump.
Hey Max, I like watching your video. Not just the information you have on each but the way you handles the video pause and resume.. Its really awesome. I have question which I been searching across to find an answer. I have a 2009 C50 and it has the fuel bar always on 1 bar even when the tank is full . Do you know why?
Hi Bijoy, I would first check the fuses under the left side rear cover. If they are good remove the Speedometer/ Dash unit. Unplug it then plug it back in and try it to see if it works. If not it must be the sending unit in the tank. I can not find it in the book but I think the wire I plug in at 17;10 on the video goes to it. You may want to talk to a dealer about this problem. If I can find anymore about it I will post it to you, Norman.
@@bijoybn The fuel sender has to be in the tank I just can't find anything on it. Does any codes come up on your dash? If so you can try clearing the code.
@@2001himax no code.. The bike had not be ridding for a while.. So i am guessing the floater is stuck.is this common? . I checked under tank and also fuel dash connector.. They all look fine.. Fuse yet to check.. Its raining here and i dont have a closed garage.. I will check fuse and will let you know..
What a great video for those of us with a problem where the tank has to be entered from below. My problem is I had to have some surgery and thus the my 2006 C50 was idle for nearly a year. I did not have a full tank of gas and the inside of the tank rusted...I did not even know that could happen....in any event, now I am going to have to clean and seal the tank. I plan to try vinegar to remove rust and then use tank sealer purchased through Amazon. Problem. I have not yet removed the fuel filter etc, but seeing the wire you un coupled remaining in the tank makes me wonder if I can actually use the vinegar and sealer unless such wiring is removed. Have you ever had to deal with this problem?
Hi George, I have never had this problem. Use a hose to remove all the gas from the tank that you can so when you remove it it makes it easy to handle it. Once the tank is off remove the gas cap off and turn the tank over and get all the rest of the gas out. Next remove the fuel pump from the bottom of the tank like I did in the video. Let the tank dry out. If you have a compressor you can put a hose in the tank then open the air line and let this blow air through the tank till it is dry. I show a connector wire that goes into the tank, I can't remember what that goes to and could not find it in the book. You can take a small mirror and flashlight to see inside the tank as what is in there. I myself would not use any cleaner or sealer in my tank. I would get a long thin wire brush that is bendable { Harbor Freight } and work the tank from the bottom and through the top to remove all the rust I can. Take a shop vac and slide a piece of garden hose into the hose of the vac and tape it up. Use the other end to put into the tank and work it all around. You have looked into the tank and know if there is anything to stay away from. This will take time. Clean, clean and clean some more. Once done replace the fuel pump then put some gas in the tank and shake the tank , dump the gas out. Do this several times. Put the tank back on the bike. if any rust remains the fuel filter will take care of it. Now any time the bike is to set a week or longer have a full tank in it. I use to fly. All aircraft would fly then be filled with fuel so as it set it would not rust in the tank. My plane was a kit plane and had a plastic gas tank and was not a problem. It could get water in the gas so there was a fuel line that was under the plane that I put a jar under and then opened a valve and let some fuel run into the jar so I could check for water in the tank. Hope this helps. This is how I would handle this problem. Norman.
@@2001himax Norman, many thanks for your thoughts about how to proceed. This was a new problem to me as I had never heard of rust inside a tank...the older I get the more I learn. I already have the tank off but have not removed the fuel pump yet...your video is great for the way to proceed. the gas cap inlet has a lip which will need special attention to clean. From what I have read, rust is now a common problem of all metal tanks due to the ethanol added to fuel...I try to run non ethanol in my mower etc. Fortunately my tractor has a plastic tank and a way to drain water also as condensation in the diesel occurs. I put additives in it as precaution. Seems it is always something.....best regards and thanks again.
@@George1mac Back when I was young there was nothing in the tank but gas. We would get rust from moisture but how we took care of it was to get a cup of small gravel, wash it real clean, put it in the tank and shake it madly. Rinse it with water and repeat several times. Today you can't do it because there are things in the tanks. When you look in your tank see if you can see where that wire goes and let me know. Norman. Glad the video helps you.
@@2001himax Norman, I am not a spring chicken either....soon to be 69. I have ridden a motorcycle of some variety since age 18 and I never had rust occur in any tank....perhaps lucky. Before I found your video, I had looked up how to clean the tank, and many said to put BBs or such in to help clean while others said use vinegar and one said to use Milkstone remover which is phosphoric acid solution from Tractor Supply. Sealer was recommended due to flash rust which will occur after the treatment. I had already bought the vinegar and Sealer (POR-15 fuel tank sealer) My neighbor is a good mechanic and he was going to help. Once we got the tank off, we both scratched our heads as we had forgot the fuel pump etc was inside the tank, so we pondered how it can be sealed with the POR. I will take my bore scope and look well inside when we get to that stage....thanks...George
@@George1mac Hi George, Watch some other videos and you can see people using acid to clean out the tank. Some show they are cleaning out the old sealer with acid that has flaked off. Does the sealer only last so long? Has the rust under the sealer made it come off ? I would love if you would make a video as you decide what to do. Also show on your bore scope what else is in the tank. You are on the right track. Send me a link to your video to ( paulymax@comcast.net ) if you make one. Your video would help so many people. Man it's like 15 degrees here in Western Pennsylvania. Now you see why I put a furnace in my workshop. All my best to you and your family and your friend helping you. Norman.
Hello, good morning, very good information you share. Where you bought the computer for the Suzuki Boulevard motorcycle, you have the name of the store or the address. thank you so much
I got it from E-Bay. I put in salvage parts for the Suzuki Boulevard. I don't remember the seller. Sometimes you can find parts from wrecked bikes and they will have all the good parts for sell. Hope this helps. Norman. Try Amazon too or Google bike salvage parts and put in the year and make of your bike.
Found code C40. That means it must be the ( Idle Speed Control ). I am putting off taking it to a dealer due to the cost. Leaving it go a while but will get back to it.
Hi Garry, Just saw your comment. They have some new cars that have in tank fuel pumps so the wires have to down inside to run them. Aircraft have tubes that run through the wings, that is where the fuel tanks are, and there is lots of wires in side the tubes. Norman.
Norm your videos are extremely helpful for us Boulevarders !
Thank you for the detailed explanation !
Thank you for watching. Norman.
Dear Norman,
Great video as usual. Looking at the fuel pump assembly I want to share my experience on a M50 which is a similar bike. My bike suddenly died one day while riding and wouldn't start while the engine kept cranking. I was lucky to find a mechanic who helped me fix the issue. Nowhere in the service manual was mentioned the fault we discovered. There is a little thermistor attached on a bracket that goes around the actual pump. The soldered connection on the wire had broken due to corrosion which prevented the fuel pump from running and the bike would not start. A new solder solved the issue.
Brother, I have to say thank you once again, I've been watching your videos for the last two months, your explanations and attention to detail allowed me to turn a junked, mistreated M50 into my daily, rebuilt from the bottom up, I greatly appreciate it.
Thank you so much for your comment. Glad it helped you. Norman.
Good evening Norman,
First thank you for this completed thoroughly video. I have a 2008 Boulevard C50T that I bought from a gentleman who let the bike sat in his storage shed for 6 years. The gas tank was rusted bad inside. The fuel pump inside the gas tank was badly rusted, and plastic wire cover harness broke into pieces when I pulled it out. So here is a list of things that I have done so far but still couldn't get the bike started:
1) Cleaned the inside tank thoroughly.
2) Removed, cleaned and test the two injectors. I verified that the solenoid on both injectors were working.
3) Put in the brand new fuel pump that I bought on eBay for $170.
4) Installed a brand new battery.
After I have everything put back together, pushed the start button, the engine turning but not fired up.
I checked the spark plugs and there are sparks on all 4 plugs. I tried to narrow down the problem by trying to spray the starting fluid directly into the upper cylinder valves to see if it started. Yes it did started with the starting fluid until it ran out. So I think the only thing left for me to check is the fuel pump. My question to you is is there a way to manually check to see if this new aftermarket fuel pump from eBay is a good or bad one?
Much appreciate it if you can provide me any lead on this. Thanks in advance!
With that rust in the tank you may have some rust in the hose that feeds the tank. The gas line you unhook from the tank has a check valve so you undo the line from the connector and very little gas runs out of the tank. It could have some rust in there. When you first turn the bike on do you hear the pump build up pressure then stop ? The gas system has a pressure system. Something to think about. Norman.
How did you clean the inside of the tank? I’m having the same issue, and I’m wondering what is the best way to clean it
@@danieldyck720 Look in the tank and if there is rust in it, what we did in the old days, Take small gravel and wash it so it is very clean. Put it in the tank and shake it turning the tank as you do this. It will knock the rust loose then flush it out a few times till it's clean. They make a product that you pour in the tank and you turn the tank and it puts a coating in it. Norman.
I brought old bike thanks champs you save my times.
Glad it helped you. Norman.
Thanks again for your videos again. Getting my c50 serviced where I live in Thailand is not really easy. I would have to ship it to Bangkok 400 miles away to get it to a qualified dealer.
Thank you so much for this video. Had to replace the pump on my C50T and this helped me out a lot.
Glad I could help. Thank you for watching. Norman.
Man thank you for that video you save me so much money I watched it about three times and had no problem installing my fuel pump keep putting up videos thanks
Hi Charles, Thank you for watching and your comment. Norman.
Hi NORMAN, great info I'm confident that you will solve this problem "I have sound now " best regards to you and lois ,
...ron..
Hi Ron, Always good to hear from you. I think I am getting closer and closer. Hope the computer does it. Stay home and stay safe. Norman
Great video!
Thank you for this. I had my pump go out and this was the only video on the subject. Without it, it would have been quite an ordeal, but with this video, it was pretty straight forward! Thank you!
Hi Jorge, Thank you for your comment. Norman.
Nice video and very helpful but , How do you clean bomb's filter? Or is it better to change ?
Thanks Norman 👍
Thank you for watching. Norman
Hello sir, I have been watching your vidoes and just wanted to say they are great! Thank you for putting so much effort into them to help others!! So I just purchased a 2006 C50 from a friend and it is having a fuel issue I believe. For some reason when he got it from someone else about 6 months ago he drained the tank and then put 87 in it. Since then he says it has ran "funny". So it will start but you have to constantly move the throttle back and forth vigoursly. Then you can get it to move by keep doing the same throttle madness. If you are not fast/hard enough on a constant basis it will die. The bike also has a Fi2000, idle/fuel control thing attached to it?? Never heard of this and will need to research that as well. Do you have any ideas for the issue I mentioned? Any help or guidance would be greatly appreciated! I just purchased this last weekend and I haven't done anything yet. Figured first steps would be check/clean fuel filter, pump, etc etc.
These bike are known to have problems like this. All my research comes up with Take It To The Dealer. I gave up on mine for a while but hope to get back to it sometime. Seems there is no easy fix. Norman.
What is the purpose of the connector inside the tank? I have a 2006 Boulevard C50 and I’m replacing the fuel pump assembly. However, mine does not have that connector. Is it essential?
Hi Joseemc21, I just saw your comment. The 2006 may be different than the 2012. My bike has the fuel pump in the tank so the wire to run it goes down in the tank to get power to the pump.
Hey Max,
I like watching your video. Not just the information you have on each but the way you handles the video pause and resume.. Its really awesome.
I have question which I been searching across to find an answer. I have a 2009 C50 and it has the fuel bar always on 1 bar even when the tank is full . Do you know why?
Hi Bijoy, I would first check the fuses under the left side rear cover. If they are good remove the Speedometer/ Dash unit. Unplug it then plug it back in and try it to see if it works. If not it must be the sending unit in the tank. I can not find it in the book but I think the wire I plug in at 17;10 on the video goes to it. You may want to talk to a dealer about this problem. If I can find anymore about it I will post it to you, Norman.
@@2001himax thank you.. I will check and let u know.
@@bijoybn The fuel sender has to be in the tank I just can't find anything on it. Does any codes come up on your dash? If so you can try clearing the code.
@@2001himax no code.. The bike had not be ridding for a while.. So i am guessing the floater is stuck.is this common? . I checked under tank and also fuel dash connector.. They all look fine.. Fuse yet to check.. Its raining here and i dont have a closed garage.. I will check fuse and will let you know..
Try this. Have about two thirds gas in the tank and rock the bike front to back and side to side. It may free up the gas sender. Worth a try.
What a great video for those of us with a problem where the tank has to be entered from below. My problem is I had to have some surgery and thus the my 2006 C50 was idle for nearly a year. I did not have a full tank of gas and the inside of the tank rusted...I did not even know that could happen....in any event, now I am going to have to clean and seal the tank. I plan to try vinegar to remove rust and then use tank sealer purchased through Amazon. Problem. I have not yet removed the fuel filter etc, but seeing the wire you un coupled remaining in the tank makes me wonder if I can actually use the vinegar and sealer unless such wiring is removed. Have you ever had to deal with this problem?
Hi George, I have never had this problem. Use a hose to remove all the gas from the tank that you can so when you remove it it makes it easy to handle it. Once the tank is off remove the gas cap off and turn the tank over and get all the rest of the gas out. Next remove the fuel pump from the bottom of the tank like I did in the video. Let the tank dry out. If you have a compressor you can put a hose in the tank then open the air line and let this blow air through the tank till it is dry. I show a connector wire that goes into the tank, I can't remember what that goes to and could not find it in the book. You can take a small mirror and flashlight to see inside the tank as what is in there. I myself would not use any cleaner or sealer in my tank. I would get a long thin wire brush that is bendable { Harbor Freight } and work the tank from the bottom and through the top to remove all the rust I can. Take a shop vac and slide a piece of garden hose into the hose of the vac and tape it up. Use the other end to put into the tank and work it all around. You have looked into the tank and know if there is anything to stay away from. This will take time. Clean, clean and clean some more. Once done replace the fuel pump then put some gas in the tank and shake the tank , dump the gas out. Do this several times. Put the tank back on the bike. if any rust remains the fuel filter will take care of it. Now any time the bike is to set a week or longer have a full tank in it. I use to fly. All aircraft would fly then be filled with fuel so as it set
it would not rust in the tank. My plane was a kit plane and had a plastic gas tank and was not a problem. It could get water in the gas so there was a fuel line that was under the plane that I put a jar under and then opened a valve and let some fuel run into the jar so I could check for water in the tank. Hope this helps. This is how I would handle this problem. Norman.
@@2001himax Norman, many thanks for your thoughts about how to proceed. This was a new problem to me as I had never heard of rust inside a tank...the older I get the more I learn. I already have the tank off but have not removed the fuel pump yet...your video is great for the way to proceed. the gas cap inlet has a lip which will need special attention to clean. From what I have read, rust is now a common problem of all metal tanks due to the ethanol added to fuel...I try to run non ethanol in my mower etc. Fortunately my tractor has a plastic tank and a way to drain water also as condensation in the diesel occurs. I put additives in it as precaution. Seems it is always something.....best regards and thanks again.
@@George1mac Back when I was young there was nothing in the tank but gas. We would get rust from moisture but how we took care of it was to get a cup of small gravel, wash it real clean, put it in the tank and shake it madly. Rinse it with water and repeat several times. Today you can't do it because there are things in the tanks. When you look in your tank see if you can see where that wire goes and let me know. Norman. Glad the video helps you.
@@2001himax Norman, I am not a spring chicken either....soon to be 69. I have ridden a motorcycle of some variety since age 18 and I never had rust occur in any tank....perhaps lucky. Before I found your video, I had looked up how to clean the tank, and many said to put BBs or such in to help clean while others said use vinegar and one said to use Milkstone remover which is phosphoric acid solution from Tractor Supply. Sealer was recommended due to flash rust which will occur after the treatment. I had already bought the vinegar and Sealer (POR-15 fuel tank sealer) My neighbor is a good mechanic and he was going to help. Once we got the tank off, we both scratched our heads as we had forgot the fuel pump etc was inside the tank, so we pondered how it can be sealed with the POR. I will take my bore scope and look well inside when we get to that stage....thanks...George
@@George1mac Hi George, Watch some other videos and you can see people using acid to clean out the tank. Some show they are cleaning out the old sealer with acid that has flaked off. Does the sealer only last so long? Has the rust under the sealer made it come off ? I would love if you would make a video as you decide what to do. Also show on your bore scope what else is in the tank. You are on the right track. Send me a link to your video to ( paulymax@comcast.net ) if you make one. Your video would help so many people. Man it's like 15 degrees here in Western Pennsylvania. Now you see why I put a furnace in my workshop. All my best to you and your family and your friend helping you. Norman.
Hello, good morning, very good information you share. Where you bought the computer for the Suzuki Boulevard motorcycle, you have the name of the store or the address. thank you so much
I got it from E-Bay. I put in salvage parts for the Suzuki Boulevard. I don't remember the seller.
Sometimes you can find parts from wrecked bikes and they will have all the good parts for sell. Hope this helps. Norman. Try Amazon too or Google bike salvage parts and put in the year and make of your bike.
Does anybody know if the fuel level indicator is attached to anything?
I would think it would have to be to send a signal to the fuel gauge. The signal would come from the works in the gas tank.
So what solved your issue?
Found code C40. That means it must be the ( Idle Speed Control ). I am putting off taking it to a dealer due to the cost. Leaving it go a while but will get back to it.
What model number is the big o ring
Hi Cole, I would go to the Suzuki dealer to make sure you get the right one for your year of bike. Norman.
...wow, electrical wiring inside the gas tank. Didn't know they did that. Sounds dangerous.
Hi Garry, Just saw your comment. They have some new cars that have in tank fuel pumps so the wires have to down inside to run them. Aircraft have tubes that run through the wings, that is where the fuel tanks are, and there is lots of wires in side the tubes. Norman.