Hi all,
This is my first post on this site. My buddy has a 03 SV650 and he told me to give it the once around so i took it for a ride. Instantly i noticed the wine of the fuel pump and then the power cutoff at around 7000rpm. So I guessed either the pump motor was busted or the fuel filters where clogged. so it really is up to the user 260$ fuel filter, mod the filter or clean it.
Stuff needed:
-Fuel hand pump
-container to put the old fuel that is in the gas tank in
-clean gas (Has to be clean as possible)
-rags (For cleanup and gas spills)
-metric allen key set, 10 mm socket with extension
Steps:
Removal of Tank
1.remove small black plastic covers from the sides of bike
2.remove seat
3.grab the fuel tank stand from under your passenger seat
4.unbolt the front of your tank and prop it with stand
5.unplug the wiring harness, fuel line and the two breather lines
6.unbolt the base of the tank and lift it off
7.empty tank (as complete as possible to get rid of the crap)
Disasembly of Fuel Pump
1. take heat shield off of the bottom of the tank
2. unbolt the fuel pump from the tank
3. wiggle the fuel pump out of the tank (it is a little tight)
4. place fuel pump on a nice clean area (and clean your hands damn it)
5. unbolt the three wires at the base of the fuel pump
6. unscrew the two spots on the sides and slide the fuel sensors off
7. now with a a fair tug pull the hole works away from the base.
8. now gape at all the crap that is in the base
9. pull off the screen filter piece at the base of the Pump assembly And clean it (compressed air works best but watch your eyes)
10. unclip the plastic holder from the base of the electric motor (there is two clips just lift both at the same time and pull up and don't break it)
11. pull the electric motor out
12. you should have a plastic thing with a black top on it that is your high pressure fuel filter, impeller and pressure release valve
The cleaning of the High Pressure Fuel pump (brought to you buy stupidity)
1. now take your hand fuel pump you bought and shove the push end of it into the hole at the bottom of the high pressure fuel assembly.
2. take the suck end of the hand fuel pump and put it in your nice clean gas
3. put the high pressure fuel assembly with the hose stuck in it in a container because its going to spray a bit. your going to have to hold the hose in place or figure a way to keep it in there
4. Pump until the nasties are all gone the fuel should be coming out the rubber lined hole
5. clean up the outside of the High Pressure Fuel filter pump assembly
Reassemble in reverse order (do a criss cross pattern when tightening up the fuel pump to the tank) and put Clean fuel back in the tank or filter your fuel you took out and put it in. Just make sure its clean or you might as well have not done this whole thing.
Start the bike up and go for a ride everything should be good. and now for some pictures. Oh and I am not at fault for any damage to yourself or your motorcycle by following these instructions and i would highly recommend getting the service manual for the bike (you can find some PDF copies floating around).
This is the crap that came out of just the High Pressure Fuel Pump filter
![Image]()
This is the setup
![Image]()
Thats the High Pressure Fuel Pump filter assembly and the fuel pushed trough it
![Image]()
Since this is my first post if there is anything wrong with it tell me and i will fix thanks guys
This is my first post on this site. My buddy has a 03 SV650 and he told me to give it the once around so i took it for a ride. Instantly i noticed the wine of the fuel pump and then the power cutoff at around 7000rpm. So I guessed either the pump motor was busted or the fuel filters where clogged. so it really is up to the user 260$ fuel filter, mod the filter or clean it.
Stuff needed:
-Fuel hand pump
-container to put the old fuel that is in the gas tank in
-clean gas (Has to be clean as possible)
-rags (For cleanup and gas spills)
-metric allen key set, 10 mm socket with extension
Steps:
Removal of Tank
1.remove small black plastic covers from the sides of bike
2.remove seat
3.grab the fuel tank stand from under your passenger seat
4.unbolt the front of your tank and prop it with stand
5.unplug the wiring harness, fuel line and the two breather lines
6.unbolt the base of the tank and lift it off
7.empty tank (as complete as possible to get rid of the crap)
Disasembly of Fuel Pump
1. take heat shield off of the bottom of the tank
2. unbolt the fuel pump from the tank
3. wiggle the fuel pump out of the tank (it is a little tight)
4. place fuel pump on a nice clean area (and clean your hands damn it)
5. unbolt the three wires at the base of the fuel pump
6. unscrew the two spots on the sides and slide the fuel sensors off
7. now with a a fair tug pull the hole works away from the base.
8. now gape at all the crap that is in the base
9. pull off the screen filter piece at the base of the Pump assembly And clean it (compressed air works best but watch your eyes)
10. unclip the plastic holder from the base of the electric motor (there is two clips just lift both at the same time and pull up and don't break it)
11. pull the electric motor out
12. you should have a plastic thing with a black top on it that is your high pressure fuel filter, impeller and pressure release valve
The cleaning of the High Pressure Fuel pump (brought to you buy stupidity)
1. now take your hand fuel pump you bought and shove the push end of it into the hole at the bottom of the high pressure fuel assembly.
2. take the suck end of the hand fuel pump and put it in your nice clean gas
3. put the high pressure fuel assembly with the hose stuck in it in a container because its going to spray a bit. your going to have to hold the hose in place or figure a way to keep it in there
4. Pump until the nasties are all gone the fuel should be coming out the rubber lined hole
5. clean up the outside of the High Pressure Fuel filter pump assembly
Reassemble in reverse order (do a criss cross pattern when tightening up the fuel pump to the tank) and put Clean fuel back in the tank or filter your fuel you took out and put it in. Just make sure its clean or you might as well have not done this whole thing.
Start the bike up and go for a ride everything should be good. and now for some pictures. Oh and I am not at fault for any damage to yourself or your motorcycle by following these instructions and i would highly recommend getting the service manual for the bike (you can find some PDF copies floating around).
This is the crap that came out of just the High Pressure Fuel Pump filter
This is the setup
Thats the High Pressure Fuel Pump filter assembly and the fuel pushed trough it
Since this is my first post if there is anything wrong with it tell me and i will fix thanks guys
