Removing Fuel Pump on a XB12R

[tut32359]

Ok,We have put on all the cosmetic parts on my sons 2004 XB12R. We are going to put in a new fuel pump and filter.We have the 4 mounting bolts out and are using one of them in the center hole,but its stuck in there pretty good.
This bike has been sitting up for awhile,the gas was bad and when we drained it we got a good bit of a oily mix that came also. Ive soaked the tank with Kerosene to help break it all loose,but we cant get the pump housing to break loose. Any one have any suggestions, Thanks for your help, George

 

[adjwoolley]

Keep working it. Try a screw driver without eating up the pump. Try a rubber mallet to try and break it free. Once you get it out I strongly recommend replacing the 2 large O rings that seal the pump to the frame and be careful not to cut the O rings on re-install.

 

[buellxb9rs]

Take a piece of steel and bend the two ends to god on each side of the back of the pump assembly against the frame(basically a u shape). Drill a hole in the middle to put a bolt through to screw into the pump and it will break it loose. Just don't tighten the bolt too far or it will break though the other side.

 

[tut32359]

That's what we are doing,tapping it,havent tried to get a screwdriver wedged in yet.Took a break for to night,we will start again on it tomorrow. Any idea where to get new orings at, Thanks

 

[tut32359]

Bending the steel to use as a type of puller sounds good, We will try that tomorrow, Thanks

 

[DualSportDad]

I ussuallu wedge ascrew driver between the pump and the frame area by the left outside edge. It will mark up the finish a little.

I got my o rings at the hydrolic supply shop, aeroquip. The o-rings are 3 and 3/16 o.d. if I recall. I can't remember the I.d, or o.d. part. Buy a 2 or 3 pair in case you pinch one. O used marine grease to lube the o rings before I installed them.

 

[tut32359]

Thanks for all your help, I will try some of all of it till it comes off. Hopefully will update tomorrow night with a good news.

 

[07Bolt]

Take a piece of steel and bend the two ends to god on each side of the back of the pump assembly against the frame(basically a u shape). Drill a hole in the middle to put a bolt through to screw into the pump and it will break it loose.

That is the best way. It slips right out of the cavity. No damage whatsoever.

 

[mrNICEGUY]

Pump can be pulled out without removing frame or other work, but you need to rotate the pump 180 degree so the hoses and pump can turn enough inside the the frame. Also needs a bit jiggling...

 

[tut32359]

Weve removed the rear tire and let the swingarm drop.Thanks for the info on turning 180 to get it out,we will give a update tonight.

 

[buellxb9rs]

I removed the rearwheel and dropped the top bolt out of the shock after scratching the swingarm the first time by not doing that.

 

[nicholas900]

I pulled mine out but my swing arm was off. I just screwed a bolt into the center hole made for puller use. Then grabbed the bolt with a pair of vice grips, gave it a little wiggle just to see how tight it was gonna be. It popped right out easy. Probably not easy with the swing arm on though to get a straight pull this way.

 

[tut32359]

K, We got the pump off. I connected a sturdy piece of flat bar.I extended the bar past the fuel pump and connected the bolt to the bar where I drilled a hole.Used a wedge on the tank and it finally gave way.
There is a lot of black residue in and around the Fuel Pump mounting area,but I will clean that. Here are a couple pics of the pump. Ive read the other post about using aftermarket pumps, fuel filter and pre-filter and which auto stores have them.
What I haven't been able to find or maybe I overlooked it,is the round part below the fuel filter.Its attached in between the pump and filter.Is this a regulator.Where can I get this part? Im going to first try and clean it,but not sure if that's gonna work.
I really appreciate all of the input Im getting on the forum.My Son is very ready to get this on the road,but we are taking it one step at a time. Thanks

 

[buellxb9rs]

Your best bet is to buy a used fuel pump assembly off of ebay. Usually $40-60 bucks. That assembly is pretty bad. The round piece is the regulator erikbuellracing has some not sure off hand of they have a factory one and harley has the stock ones they can order.

 

[tut32359]

Thanks , I will post a WTB here also and see if anyone has one. Thanks