Aftermarket (replacement) Fuel Pump

[MartinKemp]

Hi all,

Can anyone point me to an aftermarket fuel pump? A while back I got one from Quantum (link below). The first one I received didn't work. They sent a replacement. The replacement has worked perfectly for 2 seasons (15,000 miles), but yesterday became intermittent (sticks, until I tap on it, then it runs again).

Anyway, just looking for options.

Thanks
Martin

https://www.highflowfuel.com/i-23443569 ... -1063.html

[triton28]

If you haven't seen this: https://amervoyassoc.org/techtipsXII2.p ... Pump_Point it may be of some help. It is from the Tech Center on the AVA Home page.
Sorry I cannot recommend a supplier.
Dave

[Barry]

So I've saved some stuff over the years in case this wonderful forum ever disappears. Hope this is helpful. Here's what I have on fuel pumps:
FUEL PUMP

Date Posted: Fri May 12, 2006 11:00:14PM
Author: Bill Stanley
Subject: Re: Pump AND Regulator
In reply to: DaveC( Hutto) 's message, "Pump AND Regulator" on Fri May 12, 2006 3:32:44PM

Go to NAPA and get their part # 610-1050. Should be aroung 30 bucks. It will shoe horn in place of where the old pump came out of. You will need a little ingenuity and fuel hose, but it is not that hard. Hard wire in to the existing system. The little pump is a solid state clicker type pump. One of the benefits of this pump is that it works off the ign. key on mode. If the bike sets several days and the fuel draining down. Just turn the ign. key on for a few seconds and this little pump will pressurize the system. The bike starts instantly. I've had one on my ride for 4 years in some intense heat, works flawlessly. Ilove it.

Bill in Phx.

VXII fuel pumps- one thing that seems to come up from time to time in my e-mail is a question about this component. There have been quite a few failures of the fuel pump, particularly in earlier models, so I thought you might like a little more information on this subject.

Since its' inception, the VXII has used two different pumps, p/n 49040-1054 for the 1986-1991 models, and p/n 49040-1063 for all the others thru 2003. the -1063 pump is also used on all the carbureted 1500 classic model vulcans. All the failures I've seen have been on the earlier pumps, but I have heard of occasional failures in the new ones, too.

The fuel pump is designed to operate when the engine starter button is pushed and when the engine is running. It is not wired to run any time the key switch is turned on because this could cause a fire hazard in an accident. There are four wire leads attached to the pump itself; black/yellow, black, blue, and green. The red wire becomes hot when the starter button is pressed, with the black/yellow acting as ground. Once the engine fires, and the starter button is released, the blue wire becomes hot, and the green acts as ground. As with any electrical component, all these wires and connectors must be clean and solid for the pump to work. Also note that
the wires change colors when they exit the four pin fuel pump connection.

Some VXII riders carry spare fuel pumps with them on trips in case they have a failure. It's not my place to tell anyone what to take or leave home on a trip. I have fixed faulty fuel pumps alongside the road and have never carried a spare. The fuel pump has a rubber cap on one end with a Philips head screw that is epoxied in place. The epoxy can be scraped off, giving access to the screw. Once this is done, the rubber cover can be CAREFULLY worked off, taking care
not to damage the wires that run through it.

Once the cap is fully off, you will notice a pair of breaker points inside, pretty similar to what all
ignitions used, before the advent of the electronic units. All the fuel pumps I have repaired had failed due to these points being burned. To repair them, you will need some emery cloth, a piece of which you should carry with you anyway. Take a piece of the cloth about double the length needed to fit inside the points and leave a piece to fit in your hand. Now double it over, carefully work it between the points, hold them close with light pressure, and file them with the cloth. Take off only enough material to smooth the burned spot. Once you have done this, hook the wiring back up, hit the starter button, and see if the pump turns on. If it does, you're good to go, if
not you may have to file some more. Of course, to do this, you have to get the pump out in the first place. The service manual details a ridiculously long procedure that includes removing the
fuel tank. Forget all that and do this; remove both chrome side covers and the painted covers with the "Voyager XII" emblem. On the right side (when seated on the bike), you will see two bolts that hold a bracket on, along with two wiring connectors. Disconnect the connectors and take the bolts out (10mm wrench). Now go to the other side and remove the radiator overflow bottle. It is held on with one bolt and a press fit bullet shaped fitting that goes into a rubber grommet behind it. The grommet may follow it out, don't worry about it for now. Let the bottle hang by its' hoses. Now look in the space behind it and you will see the fuel line coming out of the bottom of the
fuel tank. Pinch it off with a forceps or small needle nosed vise grips (my preference, they are handy for many things). Pull it loose from the fuel filter, which is attached to the pump bracket. Take the fuel line loose from the pump that goes to the carbs. Now the bracket is free and can be pulled out from the right side of the bike. One other thing while you have the pump and bracket out; ALWAYS CHECK THE FUEL FILTER! Kawasaki doesn't specify a maintenance interval for the fuel filter itself, only for the hoses and fuel system. Look for rust and dirt inside the filter itself, and also check by blowing through it. The filter is a one-way unit, only blow the way the arrow points. If there is any doubt, replace the filter and save yourself some downtime on the road later. The biggest factors in the life of this filter are the amount of rust in your tank and the cleanliness of the tanks at the stations where you buy your gas.

[Barry]

Here's another alternative fuel pump from the tech tips page. https://www.amervoyassoc.org/techtipsXII.php
Another Alternative Fuel Pump Suggestion
By David Randall

In case you cannot get the fuel pump that Jeff talks about above, NAPA does have an electric fuel pump that will work. It is part number 610-1051, Posi-Flo model. It comes with an add on filter that goes between tank and pump, and all the fittings, but not any extra fuel line. You will need a little extra to to locate the Voyager original fuel filter and to add a little between pump and tank. This pump is set 1.5-4 PSI two wire design, neat and small, will mount on the regular mounting bracket that the Voyager pump is now on (with just a little rigging). It also will let you relocate the fuel filter so you can change it easier. Instead of using the long fuel line adapter that goes in the outlet end, use an elbow first, then, the adapter. Use the info Jeff provides about wiring the pump. I used the red hot wire and ground Jeff talks about, but did not cut the original plug off. Be sure to mount the back as far as you can on the original mount so the rear brake reservoir will remount with no trouble. AFter installing the pump and before putting everything back in place, I checked to make sure that everything would fit back i place just like factory. Turn the key on, wait just a minute to let it prime up. Instant start and very little gas fumes. Down the street and back, using all the throttle I could, yielded very good throttle response and very smooth running at last. Total cost for pump and supplies are $60.00 (as of 11/18/07), much better than the OEM at $175 for a new pump.


Personally, I'd pick up a used factory pump & just clean the contacts.