Fuel pump again

husaloser · Jul 30, 2015

I know it has been covered here a million times over
BUT I have a new fuel pump for my 2010 FX 450 and want to swap it out sometime soon. Is there a complete list of things i need to get to go along with the new fuel pump, Clamps tubing etc etc? I know there is a different barbed or nonbarbed attachments somewhere in there.
Also need to do the weep hole mods. Man am I a slacker, and dont get to ride the husabeast as much as I'd like . had it since 2011 and barely have 6 hrs on it.

Ruger · Jul 30, 2015

You won't need much:
- First you'll need a CA Cycleworks fuel pump.
- Next, throw the fuel line that comes with the CA Cycleworks fuel pump away. Unless they've changed their methods, the fuel line they include is just a tiny bit too big. Suitable high pressure fuel line is so stout that it does not readily compress no matter how you crank on the clamps. The pump will blow the fuel line off the pump's hose barb every time unless you use the correct ID fuel line.
- I bought 5/16 inch high pressure fuel line made by Helix Racing Products. The PN for the package of clear line three feet in length is 0706-0191. I got it from my local KTM dealership for $9.95. You can order it yourself from Parts Unlimited. This is stout stuff. The ad copy in the catalog says it is rated to 220 PSI!
- Make sure your hose clamps are for high pressure fuel injection systems. The typical gear-tightened hose clamps aren't the right type, and if you resort to them you may find that they're insufficient for keeping the hose on the fuel pump.

Ruger · Aug 6, 2015

And don't be afraid to crank down on the hose clamp at the fuel pump. I tightened what I thought was good and snug, and then pulled on the hose to check. It slid. Tightened it more and retested. It slid, but a little less readily. Get it tightened to the point where you can't get it to move no matter how hard you pull.

Why? Because that fuel pump puts out between 45 and 50 PSI, and it'll force the fuel line off the hose barb. And then you're stranded miles from where you want to be. Pushing a 250 pound motorcycle over rough terrain in MX boots is good exercise for sure, but not as fun as riding the motorcycle. Ask me how I know.

Rainerio · Aug 6, 2015

(ask me how know) that's my line!!!!

tourist · Aug 6, 2015

ask me! ask me how I know how the lower set of fuel tank / shroud bolts on a DRZ is that much longer than the upper pair that it will punch nice threaded holes in the fuel tank if you mix them up! (incidentally Weicon Repair Stick Aqua is MAGIC! ask me how i know that!)

Ruger · Aug 6, 2015

Tourist and Rainerio:
Crazy Comedy Conundrums
Preposterous Prestidigitation
Limitless Lunacy
Entertainers Extraordinaire

akshun · Aug 9, 2015

Standard pumps work fine as long as you have the later one. If you have trouble with hose clamps holding on then you are doing it wrong! The right size hose for the right size barb is a no brainer. 50 psi is not that much to overcome, you will be fine!

Ruger · Aug 9, 2015

"The right size hose for the right size barb is a no brainer."

You'd think so, wouldn't you? But the hose provided with the CA Cycleworks fuel pump was incrementally too large.

akshun · Aug 9, 2015

Yes, I agree! Another case of an aftermarket product that needs to be modified to fit. It wouldn't be that bad if they just told you that instead of you getting half way through installing it and having to get more parts! Oh well, it seems that is just how things are these days, ha ha!

Ruger · Aug 9, 2015

They'd have done much better by me if they hadn't included any fuel line with the fuel pump at all! That way I would have bought my own fuel line and wouldn't have gotten stranded six miles from home.

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Fuel pump again

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