2007 DL650A Fuel Pump Repair / Cheap - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 12 Old 10-28-2010, 08:28 PM Thread Starter
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2007 DL650A Fuel Pump Repair / Cheap

Due to sluggish behavior and a high pitch noise coming from the fuel pump on my 2007 DL650A (25,000 miles), I decided to remove the fuel pump and take a look. I found like many others on this forum, that the inlet/suction screen was totally plugged. I ordered a new inlet/suction screen and item 7 which is the plastic piece with the outlet/high pressure screen in it. Out of curiosity, I cut apart the plastic piece (with a dremmel cutter) that houses the outlet/high pressure screen. I learned that the output/high pressure screen is very thick/tough. Much stronger and tougher than a typical aluminum screen door screen. I could have easily cleaned the outlet/high pressure screen with a spray solvent cleaner and not have had to buy a new one. It would have been easy to flush the fluid both directions accross the screen with a spray cleaner nozzle such as those that come with cleaners/lubricants like aerosol WD-40. Also, the outlet/high pressure screen is not very fine. The mesh screen openings are fairly large. Fine sand would probably be able to go through the screen. It it obvious that Suzuki intended for the inlet/suction screen to do the fine filtering. The outlet/high pressure screen was probably installed to keep fuel pump parts from getting to the injectors/engine in the event the pump failed. Replacing the low pressure/suction screen was necessary due to its delicateness. The low/pressure suction screen is about $23.00 - The outlet high pressure screen part is about $95.00. Doing this again, I would have cleaned the outlet/ high pressure screen and only replaced the inlet/suction screen. I am waiting for the parts to arrive to reassemble the pump. All of the o-rings looked good and I am re-using them. I will provide an update here when I have completed this project and tested the bike. Complete new fuel pump assemblies are well over $400.00. I will have just over $100.00 in my repair job which could have been only $23.00 plus tax had I known the outlet/high pressure screen was durable and cleanable. Hope this info helps other DIY Budgeteers.

A special thanks to Grey Wolf for him leading me to helpful information sites here and at ADV Rider.
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post #2 of 12 Old 10-28-2010, 09:00 PM
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Here is the diagram. I find it odd the high pressure filter media would be coarse and the inlet screen fine. It's the other way around with the earlier pump. Are you sure you didn't just see a surrounding screen which would prevent larger stuff from getting to a finer filter inside? How about a picture? Posting the info and a picture at http://www.vstrom.info/Smf/index.php/topic,6105.0.html too would be nice as the info on the pumps came from there.


Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html

Last edited by greywolf; 10-28-2010 at 09:03 PM.
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post #3 of 12 Old 10-31-2010, 09:13 AM Thread Starter
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Screen

Grey Wolf, you are correct. I looked closer at the high pressure screen. It is two sided. One side is course and the other side if very fine. It's a double sided screen. I will post this info at the other thread soon as you suggest.

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post #4 of 12 Old 11-15-2010, 07:56 PM Thread Starter
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Success

Bike is all back together and runs like a top!

2007-DL650 WeeStrom ABS

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post #5 of 12 Old 11-19-2010, 08:40 AM
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I too had some significant hesitation under WOT, like no fuel or vapor lock. When I took mine apart and cleaned the filter #2 on Greywolf's added pic, I can only describe the thing as looking like a used Skoal Bandit. I soaked mine in mineral spirits for half hour and blew it out with 15psi on the air hose. It runs like a top again. I did some other stuff while I had the bike tore that far apart (TPS adjust and put in iridium plugs), but am pretty sure it was the filter.
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post #6 of 12 Old 12-29-2010, 11:55 AM
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I have over 90,000 miles on my 2006 DL650.

My fuel pump has been making noise and there is a flat spot in the engine power that initially started around 8,000 rpm that has been getting larger (ie: flat spot over a wider range.)

I suspect the filter is clogged so am going to take it apart and check it and clean if needed.

Are there any little gotchas I need to worry about befroe doing this?

Thanks,

..Tom

2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 195,000+ km, 121,000 miles.

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


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post #7 of 12 Old 12-29-2010, 01:29 PM
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See External Fuel Filter modification for pump info. Cleaning the high pressure filter isn't a good option. The external filter modification is probably your best bet. Otherwise, it's a expensive replacement. Do the flow test first to make sure a clogged filter is the problem.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #8 of 12 Old 12-29-2010, 02:02 PM
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Quote:
Originally Posted by greywolf View Post
See External Fuel Filter modification for pump info. Cleaning the high pressure filter isn't a good option. The external filter modification is probably your best bet. Otherwise, it's a expensive replacement. Do the flow test first to make sure a clogged filter is the problem.
Hi Pat,

Thanks for the comment. I have been reading that thread and in doing so it occured to me that cleaning might work. Can I ask why it isn't a good option?

..Tom

2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 195,000+ km, 121,000 miles.

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


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post #9 of 12 Old 12-29-2010, 04:56 PM
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Quote:
Originally Posted by V-Tom View Post
Hi Pat,

Thanks for the comment. I have been reading that thread and in doing so it occured to me that cleaning might work. Can I ask why it isn't a good option?

..Tom
It just doesn't seem to work for long if at all. The crud gets embedded in the filter material and doesn't come out easily.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #10 of 12 Old 12-29-2010, 06:02 PM
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Thanks Pat, I'll plan on a bypass..

..Tom

2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 195,000+ km, 121,000 miles.

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


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