Join Date: Jul 2005
Location: Hillsdale Michigan
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.
2007-DL650 WeeStrom ABS
"Hey Harley Riders, 20 grand and 20 miles doesn't make you a biker"