Fuel Pump disassembly question - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL650 and DL650A - 2004 to 2011 DL650 from 2004-2006 (K4-K6) and DL650 or DL650A from 2007-2011 (K7-L1)

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post #1 of 10 Old 10-18-2019, 12:56 PM Thread Starter
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Fuel Pump disassembly question

Good day all

I have a 2006 dl650 with 68,000 km. Bought used in 2012 with 8,000 km.
Lately the fuel pump has been whining (not constantly) so I decided I would try to replace the fuel pump strainer.
When I pulled the pump I found what looks like some sort of sealant on the outside of the pump (red arrow), has anybody seen this before or do all the fuel pumps have this?
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File Type: jpg Fuel Pump Assembly with arrow.jpg (527.4 KB, 7 views)
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post #2 of 10 Old 10-18-2019, 02:23 PM
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I don't think the fuel pump for a 2012 DL650 is the same as for 2006.

Don't have any other answer except perhaps you should Google "fuel filter bypass" as it worked brilliantly and inexpensively on my 2006 DL650.

..Tom

My Opinion:
Vee or V= DL1000 before 2014
Vee2 or V2 = DL1000 2015 to 2019
Vee3 or V3 = DL1050 2020 to?

My Stroms:
2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 205,000+ km, 127,000+ miles.

This can help preventing from cars pulling out in front of you (SMIDSY)
SMIDSY detailed report.


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post #3 of 10 Old 10-18-2019, 02:42 PM
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Have you done the flow test? That will tell you if the main filter is blocked or not. A blocked filter can be the reason for the whining.

https://www.stromtrooper.com/dl650-d...t-results.html

Here is a picture from my old pump, looks similar:
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File Type: jpg IMG_2128.jpg (292.9 KB, 7 views)

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Blau1 2004 DL650-sold
Blau2 2014 DL1000A
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post #4 of 10 Old 10-18-2019, 04:23 PM Thread Starter
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Thanks for the photo of your fuel pump, it looks like the portion I was wondering about is the same as yours.

I have done the fuel flow test and only got 120 ml so you are most likely correct that I will not be able to get away with just replacing the fuel strainer.
That being said, I have had no problems with the running of the bike and it pulls hard all the way to redline.
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post #5 of 10 Old 10-18-2019, 04:40 PM
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It will not pull hard if go up a hill with more load on the engine if the fuel flow is that low. Do the external fuel filter modification and be done with it. The strainer is cheap to replace if it's very gummed up or brittle.
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Blau1 2004 DL650-sold
Blau2 2014 DL1000A
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post #6 of 10 Old 10-18-2019, 06:10 PM
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My '04 pump shows the sealant around that upper end like yours. When mine started to whine I just ignored it. Not many miles later I regretted that in the pouring rain on Mount Evans. The bypass is a good move.
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post #7 of 10 Old 10-18-2019, 06:46 PM
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Many long-term strom owners have had to do the bypass. Eventually, power falls flat on its face at abrupt wide throttle openings. The upside is that it'll be right again for a LONG time, my replacement Wix 33095 filter has 90k carefree miles. I may replace it some day just for the hell of it.

Take care when sizing the fuel hoses, you want to avoid any tension at the fittings, contact with wires, etc. Be sure to buy FI-rated stuff.

5/16" fuel injection hose and clamps.
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Last edited by Fox; 10-18-2019 at 06:49 PM.
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post #8 of 10 Old 10-18-2019, 09:46 PM
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Initial signs of clogged fuel filter are reduced power at torque peak in higher gears. The fuel flow can't keep up with demand and the fuel injection runs out of fuel. This gets worse over time as the filter plugs more and spreads to lower rpms and higher rpms.

..Tom

My Opinion:
Vee or V= DL1000 before 2014
Vee2 or V2 = DL1000 2015 to 2019
Vee3 or V3 = DL1050 2020 to?

My Stroms:
2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 205,000+ km, 127,000+ miles.

This can help preventing from cars pulling out in front of you (SMIDSY)
SMIDSY detailed report.


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post #9 of 10 Old 10-19-2019, 05:19 AM
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Fuel injection cleaner may help. Just an FYI.

I've had my pump start whining a few times now and a capfull of FI cleaner some k's and the whining goes away again. I do have a spare pump on the shelf but haven't needed to change it yet.

Just pointing out also that a complete replacement pump off eBay is in the $40 region and less stuffing around than doing the bypass. My OEM pump has 130,000k's and the intent is to just swap it out if it really griefs me.

There is some messing around with the fuel sensor but odds are that'll cause problems anyway just from touching the pump.

Last edited by PeteW; 10-19-2019 at 08:35 PM.
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post #10 of 10 Old 10-19-2019, 12:49 PM Thread Starter
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Thanks for all the advice and info.

I already have the strainer and will get everything else I need for the bypass.

"Winter is coming" so I might as well keep busy.
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