Concours 1400 (C14) FAQ > Engine and Controls (Fuel, Ignition, Exhaust, Sensors and the like)

Fuel Pump and Fuel Filter revisited.

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JamminJere:
I know we had a couple of good threads on the old board about the Fuel Pump and some of the problems/issues with dirty fuel over time. AussieDave (RIP) was one of the first to experience this and some of the other far riders down under..We have it in an FAQ here on the site.. However the pictures are no longer visible for me to see.

I would think every C14 will have problems with this and about 4 or 5 other models that use the same pump, (ZX6 ZX14 our bike, etc)... its just a matter of time/mileage. We basically have a fuel pump that has an internal fuel filter. Mama Kaw does not mention anything about it in the Service Manual. All fuel systems have a filter somewhere.. most are serviceable.  There are no parts available from Kaw for the fuel pump. The parts fische shows one part number/ complete fuel pump for $344.00 US today.. I've seen OEM pumps on ebay for $279.00.

What happens is eventually the filter/screen clogs with fine sediment from dirt in the gas, the pump struggles to maintain rail pressure for the injectors, it cavatates and will not be able to fuel the engine in the higher rpms, and when bad enough, the bike surges on and off like someone is playing with the kill switch. It did NOT throw an FI code on the ECU.  Can you service it yourself? And save the $300 bucks for gas when there is nothing else wrong with the pump?  Sure if you are careful.

Run the tank down well into reserve, or if you have a pump, you can pump the fuel out of the tank into a container. Remove the tank and flip it upside down on a blanket...



remove the 5 bolts holding the fuel pump in the tank.. and then remove the pump. You will have to move one of the clips to free the wire going to the pump assy.  Bring it to the bench...



Now.. looking at the bottom of the pump, behind the two wire terminals on the left side pictured, is where the fuel inlet is to the pump. By design, nothing large can get in there.. so how do we get in?

There are two phillips head screws at the top of the pump, one has a ground wire connected. remove the two screws. The top metal bracket that holds the sending unit for low fuel is on this piece. Note where the wire for it connects and remove the wire from the clips in the plastic body.. set it aside.

Using 1 or 2 flat blade screw drivers, you will see a gap around the first 1/3 of the pump body. Pry gently on opposite sides until you pop the pump top out of the o-rings holding it together.  As it comes up the rails and is removable, check the two o-rings and orientation for this part for re-assembly.

Once the top 1/3 of the pump is removed, slide the entire rest of the pump body up and off the two silver metal rails and turn it upside down. (you may get small drips of gasoline do it on a towel or shop rag). We can now see the filter bottom. It is a fine brass mesh screen impregnated with an almost cotton like material inside.. Mine was completely black and fouled with fine dirt.

Carefully work a small flat screwdriver around the screen and the plastic body that holds the screen, until you work the champhered end out of the fuel pump body and out of the pump.


PIC SHOWS TOP SIDE OF FILTER THAT GOES BACK IN TOWARDS PUMP


DISASSEMBLED PUMP

I used carb and choke cleaner and compressed air to get the worst of the crud off, and then cleaned it a second time in hot water with a little dish soap and let it soak in there for about 10 minutes then worked it around and used compressed air to remove all the water and dry it off..


DIRTY!

When cleaned, although its hard to see in the pic, the brass of the screen was clean.. and the material inside it was almost white again.


BETTER

I used a tiny bit of clear grease on the O-rings going back together.. re assembly is the reverse of tear down.



EDIT: Forgot to mention, while the pump is out, take a bright flashlight and check out the inside of the tank for dirt in the remaining gas or sides of the tank. Flush if necessary.

I also used my O-ring over in the fuel tank. Made sure it was clean.. You can use the service manual for tank removal and fuel pump removal and re-installation if you have it.

Put it all back together, and your good to go for XX,XXX amount of miles again.

Our bikes are coming up on 5 years old this July... Save yourself a real headache and put this service on your list to do before the surge bug gets your bike.. Man they run great again with a clean filter! :)

This report was done again for our lost great member AussieDave.... We miss you Davo... I hope you're having a great ride.

JJ

B.D.F.:
Nice post Jerry. I am considering another trip to the left coast and as the bike is now approaching 80K miles, I can see this would be a useful preventative maintenance issue. No issues with the bike or fuel system yet but as you mention, why wait when it is fairly easy to clean the filter. It is always much easier to do work on a bike in the garage, at the owner's convenience than it is on the side of the road... at night.... in the rain.... with bears watching.

Thanks for taking the time to share the info.

Brian



--- Quote from: JamminJere on March 21, 2012, 07:47:01 PM ---I know we had a couple good threads on the old board about the Fuel Pump and some of the problems/issues with dirty fuel over time. AussieDave (RIP) was one of the first to experience this and some of the other far riders down under..We have it in an FAQ.. However the pictures are no longer visible for me to see.

<snipped instructions>

Our bikes are comming up on 5 years old this July... Save yourself a real headache and put this service on your list to do before the surge bug gets your bike.. Man they run great again with a clean filter! :)

This report was done again for our lost great member AussieDave.... We miss you Davo... I hope you're having a great ride.

JJ

--- End quote ---

Jay:
Since this C14 "filter" is built into the fuel pump that resides inside the gas tank, it appears there is no way to prevent an inevitable clog.

Is there anything we can to to avoid a fuel pump tear-down?
Maybe pump gas through a coffee filter?

lt1:
Thanks.  Any ideas what a reasonable service interval would be?

VirginiaJim:
Actually, Davo's fuel filter issue post is still available through our C14 Wiki area....

http://www.zggtr.org/index.php?topic=1238.0

Davo  RIP....  :'(

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