Road Star Clinic - Relocate your fuel pump (under side cover)

Relocate your fuel pump (under side cover)

Written by John Cosentini

Friday, 11 June 2004

Reprinted by permission from Mr Tidy's tech tips

I don't remember who came up with this idea, but I think this is a VERY CLEAN relocation scheme for the fuel pump. It may have been Bill H I think. I can't take credit for all of this. Many Forum members have contributed. John Cosentini

The guy that came up with the idea woke up today, errrr... Spoke
up today. RC (RCHAMER1) did the pictures and write up on the fuel
pump modification. In RC's own words..
" By the way, my installation is still working
great with absolutely no problems. I have had it this way for over 15,000 miles now."
RCHamer....

Remove Seat, Tank, Fuel cover and bracket and proceed with the rest.

The relay in the front (on my picture) is the control relay for the fuel pump.

Set up prior to moving relay to outside of
bracket.
.

Another "after relocation" shot.

After relay behind bracket is moved to the outside,
(relay moved is on the left hand side)

The fuel pump retains the rubber mount and hooks onto the bracket after you move the inner relay to the outside rear bracket.

Everything is then hidden behind the side cover with nothing showing.

Picture shows where I picked off the electrical

The blue/black wire in the corner of the relay socket is the wire you attach to for the fuel pump. Right there where you are, real nice.
I used the original connector to make replacement a snap

I used the bullet connectors with silicone jackets (like Yamaha uses for the tail light connectors)
and attached them to the fuel pump connector that was up under the tank.

This makes for a real easy change out if you ever have to replace the pump,
no more mods are ever necessary

It took about 6 1/2 feet of fuel line to do the way I routed it. I Have never had that much fuel line on a motorcycle before, maybe I can go an extra 5 miles with that amount of fuel line!!!
Another 2 views of relocated fuel pump.	2nd View
Pix to right shows how I routed across the battery box.
shows some more routing

I included 4KRZNs_left Side.jpg shows the left side after the relocation Very clean looking side now The Lightning Shift Rod, The Stainless Steel Floorboard Extension and even Mr. Tidy's 4 way flasher switch on the side cover all looks good. John Cosentini 4KRZN@Bigfoot.com http://go.to/4krzn

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only. Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure. You assume all risks associated with the use of this information. NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION. Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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Comments (3)

relocation of fuel pump
Written by Spike, on 03-27-2008 11:55
Hey I did the relocation of the fuel pump on my 2004 Roadstar. I cannot seem to get it started..I get fuel to the fuel pump but nothing to the carb...Please help....
Thank you
Spike

fuel pump relocation
Written by ZZ, on 11-21-2007 00:00
Just so I have this straight, the stock location of the fuel pump on my Roadie is in between the jugs under that little chrome cover on the left side, right? have thought to myself. having not looked, that that cover really takes away the looks to the engine. I do have a hypercharger on the other side and thought a tornado would do much to add to the opem look of the jugs. That is where harley really shines becase they don't obstruct the beauty of the engine. Hope this is not too dumb of a question.
ZZ

fuel pump relocation
Written by liteflyer50, on 10-19-2007 09:16
other than the new fuel line and tie-wraps were there any other parts and out of pocket costs that you had?

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