The Torque Gremlin/Fuel Filter Bypass SNAFU - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 4 Old 09-01-2019, 04:08 PM Thread Starter
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The Torque Gremlin/Fuel Filter Bypass SNAFU

I had some water in my tank and so decided to pull my fuel pump on my 2002 DL1000 and check the condition of the tank and do the filter bypass at the same time.
Considering how badly abused my bike was I was expecting the tank to be a disaster but was amazed to find it was nearly pristine looking. The pre filter was a little dirty but not bad.
I ran into a major problem disconnecting the wires while disassembling the pump body. One of the nuts was torqued ultra tight and the wire connector was trapped between the nut face and pump body. When I attempted to loosen it it just snapped off. Bummer.
The wiring enters the tank via three studs secured within a semi circular flange, one on either side with o ring seals. Initially this assembly looks unserviceable but it is possible to chisel out the material securing the post on the outside of the pump and replace it.
I did this, replaced the post with. 3/4” machine screw and epoxied over the screw head as they did during manufacture.
Just be very careful chiseling out the old post.
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Last edited by Rides; 09-01-2019 at 04:12 PM.
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post #2 of 4 Old 09-02-2019, 08:51 PM
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McGyver, nice pics and good attack of a problem. Hopefully you have a successful outcome.
I haven't ripped into a gas tank with a fuel pump and I don't look forward to it.
It just seems so dumb to my meager mind that an external pump doesn't exist. Burying the pump in the tank is counter intuitive to me.
That fuel level sensor that seems to be missing the top bar? F-it I know I just filled the tank and as long as the other bars work, I'm good with that.
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post #3 of 4 Old 09-02-2019, 11:36 PM Thread Starter
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I’ve owned I think 5 vintage Volvo’s and had to do the in tank pump in all of them so old hat by now. At least you don’t have to pull the tank on those like many American cars. So far sealed up fine, no sign of leakage. I figure even the most simple job can go wrong and often does, oh well. “Improvise and Overcome!”
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post #4 of 4 Old 09-03-2019, 01:45 AM Thread Starter
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Fuel pumps in tank out of necessity to prevent vapor lock.
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