Gen 1 Fuel Filter Mod & Pump Replacement

SSGT_B

SSGT_B

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Using @chrisjp guide and from some nudging by @clean lol I decided to tackle this job. I initially bought just the filter parts but after further inspection I just ordered the pump as well. Pouring out fuel from the filter side was giving mud.......... Spent about 29 bucks for 2 feet of injector hose, 4 clamps and a filter and can of carb cleaner from local auto parts store. I ordered a Bosch 69420 fuel pump off amazon for 91 bucks. That won't get her till Sunday so the final pics won't be until then.

Dissassembly

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Couple things I noticed, when I removed the FPR I noticed that the orange was torn. Anyone know where I can get a replacement? I have an orange kit but the ones in the kit are too thin.

Does anyone know if that is the stock fuel pump? I think it might have been replaced at some point.

Also plan on having injectors cleaned since I saw all the mud and crap coming from stock filter


1st set of parts

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Hmmmm with nearly 70,000 miles I’ve never opened the tank from the bottom to take a look. Performance wise there’s no indication anything is clogged. Can everything inside be replaced vs being dismantled, drilled and modified? Does the Bosch unit attach just like Suzuki’s?
 
WuzzaCBXRider said:
Hmmmm with nearly 70,000 miles I’ve never opened the tank from the bottom to take a look. Performance wise there’s no indication anything is clogged. Can everything inside be replaced vs being dismantled, drilled and modified? Does the Bosch unit attach just like Suzuki’s?
Click to expand...

you can replace the whole thing in one go for $1k from suzuki. doing the mod bypass saves you about 850$. XD
 
SSGT_B said:
Couple things I noticed, when I removed the FPR I noticed that the orange was torn. Anyone know where I can get a replacement?
Click to expand...
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SSGT_B said:
You could just replace a stock unit back into but cost is the factor for for me. I will have about 130 usd into this mod vs 4-600 to replace a factory unit. The Bosch pump has a outer sleeve that must be removed then it drops in from all that I have read.
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wow good thing your doing this....it was pretty ugly in there. how much of the tank is rusty? a few spots? a large portion? I had a few spots that I did the por 15 3 step sealing method to. used a mirror, and worked upside-down through the fuel pump hole....not fun but got it good. make sure you get your tank fixed up before you put everything back together.

that pump is not original ( likely Chinese aftermarket - Id still go with the bosch)

the o-ring is cheap from Suzuki. pretty sure I bought the same one - 7$ish.


what size drill bit did you use? your hole looks a little smaller then mine XD. I went 1/4" . if you go bigger make sure to not go through the side of the filter housing.
 
clean said:
wow good thing your doing this....it was pretty ugly in there. how much of the tank is rusty? a few spots? a large portion? I had a few spots that I did the por 15 3 step sealing method to. used a mirror, and worked upside-down through the fuel pump hole....not fun but got it good. make sure you get your tank fixed up before you put everything back together.

that pump is not original ( likely Chinese aftermarket - Id still go with the bosch)

the o-ring is cheap from Suzuki. pretty sure I bought the same one - 7$ish.


what size drill bit did you use? your hole looks a little smaller then mine XD. I went 1/4" . if you go bigger make sure to not go through the side of the filter housing.
Click to expand...
The tank has no rust that I can see. That junk was all dirt and varnish. I am thinking about using my power washer to break up the rest of the dirt inside but I don’t want to make rust. Any suggestions for tank cleaning?

The hole is a 3/16. I used @chrisjp write up for the drill size

@Kiwi Rider damn brother! Johnny on the spot! In Houston as well. You rock buddy
 
SSGT_B said:
The tank has no rust that I can see. That junk was all dirt and varnish. I am thinking about using my power washer to break up the rest of the dirt inside but I don’t want to make rust. Any suggestions for tank cleaning?

The hole is a 3/16. I used @chrisjp write up for the drill size

@Kiwi Rider damn brother! Johnny on the spot! In Houston as well. You rock buddy
Click to expand...
I would avoid using water. The steel inside will flash rust very easily. I would get a specific fuel tank cleaner if possible.
 
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