FUEL PUMP CHANGING INSTRUCTIONS

1. Provide access to the fuel pump by doing the following: To avoid the possibility of damage to the MCU circuit board, remove the MCU board and cover plate from the unit by unplugging the system wires from the MCU circuit board and slipping the wires through the cover plate slots. Do not tug on the wires, pull only on the connector bodies. Pulling on the wires can result in damage to the wire/terminal. Dismount the Inlet Air Temperature sensor from the back side of the MCU upper right mounting screw. Do not lose the spacer between the MCU card and the cover plate or the nylon washer between the sensor and the cover plate. Unbolt the throttle body from the manifold and lay the unit on a suitable support next to the engine.

If desired, the unit can be removed from the engine by the following method:

1. disconnect the spark coil driver cable from the spark coils

2. remove J1, J3, and J6 cables from unit

3. leave J4 cable and J2 cable attached to unit

4. shut off petcock on supply fuel line

5. pinch off fuel hose on return fuel line

6. remove supply and return fuel lines from unit

The unit is now free from the bike, unless the Oil Temperature sensor is installed, in which case J2 will have to be removed from the unit and remain attached to the bike. This will require that the other wires connected to the J2 connector be disconnected from the unit by unplugging the throttle position sensor, dismounting the Throttle Body Temperature sensor (the Inlet Air Temperature sensor is already free due to dismounting the cover plate above).

While the above methods are recommended, we usually just remove the two bolts that attach the throttle body to the manifold, the two bolts that attach the backing plate to the head, disconnect the throttle cables, and let the unit swing out on its hoses and wires. A rag under the unit to protect the cone is good. Use this method at your own risk, since it is easy to bang stuff up if you're not careful.

2. Remove hoses from pump inlet and outlet and remove push-on wire connectors from top of pump.

3. Loosen nuts that attach Adel clamps to backing plate (pump is held to backing plate by two MS21919-DG23 Adel clamps). The reason for not removing the mounting nuts is to avoid having to start the nut on the bolt when replacing the clamp. Starting the nut on the bolt that attaches the Adel clamp is a real pain, because the clamp is very springy.

4. Squirt some WD-40 on both Adel clamps to lubricate the clamp-to-pump interface. Note the orientation of the pump: the electrical terminals face to the front of the bike. Remove the old pump from the clamps by sliding it out the bottom.

5. Slip the new pump into the clamps. Wiggling, WD-40, and keeping the clamps straight help this procedure. Align the pump centered between the clamps, terminals to the front. Important: Keep the plastic plugs in place on the new pump. Particles greater than 70 microns, if allowed to enter the pump, will destroy it (not covered by warranty).

6. Tighten Adel clamp mounting nuts. Attach hose to pump outlet (top) with hose clamp. Plug wires on pump.

7. Reverse disassembly to re-install unit on engine. If new lockwashers are not available, use loctite. Remember to attach throttle cables before mounting unit on manifold. Do not connect fuel supply hose to bottom of pump yet. If the MCU board was removed, be careful to not reverse the plugs when re-installing it. The J4 connector at the bottom of the board gets the power/ground plug (black, red, and white wires), J1 connector on the left gets the display plug (big 16 conductor cable). Do not overtighten the screws holding the MCU card to the cover plate, they are no. 6 screws and are easily twisted off. Insure that spacers are in place between MCU circuit board and cover plate.

8. IMPORTANT: Flush fuel line. Place a can under the end of the fuel supply line. Turn on the petcock and allow a few ounces of fuel to run out of the hose. This is to flush out the fuel supply line and filter. This should be done any time the filter is removed or cleaned. Particles greater than 70 microns will damage the pump beyond repair.

9. Shut off petcock and attach fuel supply line to pump inlet. Turn petcock back on.