Replacing Your Roadstar's Fuel Pump: Step-By-Step Guide

The Yamaha RoadStar is a popular motorcycle that has been in production since at least 1999. The fuel pump on the Yamaha RoadStar is located under the left side of the tank, and it can quit at any time, leaving riders stranded. This has led some RoadStar owners to consider removing or relocating the fuel pump. While it is possible to remove the fuel pump and run the bike on gravity, this may not allow full use of the tank capacity and could lead to fuel starvation at higher RPMs. One option for those who want to remove the fuel pump is to convert to a carbureted fuel system, which does not require a fuel pump. There are also kits available that allow for the relocation of the fuel pump to a hidden location under the right side cover, decluttering the left side of the engine.

Removing the fuel pump

To remove the fuel pump from your Yamaha Road Star, you will need to purchase a kit that includes all the necessary hardware, special brackets, and instructions for a successful removal.

Step 1: Prepare the Motorcycle

• Park your Yamaha Road Star on a flat, level surface and engage the parking brake.
• Disconnect the negative terminal of the battery to prevent any accidental electrical issues.

Step 2: Drain the Fuel Tank

• Place a suitable container under the petcock valve to catch the fuel.
• Turn the petcock valve to the "off" position and unscrew the fuel hose.
• Allow the fuel to drain completely into the container.

Step 3: Remove the Fuel Tank

• Loosen and remove the bolts securing the fuel tank to the motorcycle frame.
• Carefully lift and remove the fuel tank, placing it in a safe location.

Step 4: Access the Fuel Pump

• Locate the fuel pump, which is usually found under the seat or on the left side of the tank.
• Disconnect any wiring or hoses connected to the fuel pump.
• Remove any brackets or mounting hardware securing the fuel pump in place.

Step 5: Remove the Fuel Pump

• Carefully lift and remove the fuel pump from its housing.
• Clean the area around the fuel pump to ensure no debris falls into the tank.

Step 6: Install the New Fuel Pump

• If you are installing a new fuel pump, follow the manufacturer's instructions for placement and mounting.
• Ensure all hoses and wiring are connected correctly and securely.

Step 7: Reinstall the Fuel Tank

• Place the fuel tank back onto the motorcycle and secure it with the bolts previously removed.
• Reconnect the fuel hose to the petcock valve and tighten it securely.

Step 8: Final Checks

• Reconnect the negative battery terminal.
• Check for any fuel leaks around the fuel pump and hoses.
• Start the motorcycle and observe for any unusual noises or issues.

By following these steps, you can safely remove the fuel pump from your Yamaha Road Star. It is important to refer to your specific motorcycle's manual and seek professional assistance if you are unsure about any part of the process.

Converting to gravity feed

Converting your Yamaha RoadStar to gravity feed is a popular modification, as the fuel pump is one of the more common items to fail, leaving you stranded. The process is simple and, if done correctly, will have no ill effects on your bike.

What you'll need

You can purchase a kit with everything you need to remove the fuel pump and convert to gravity feed. The kit should include:

• A Pingle High Flow Petcock
• A Road Star Adapter Plate
• A Pingle Permanent High-Flow Fuel Filter (which never needs replacing—the bronze element is cleanable)
• Premium Motion Pro Clear TYGON high-quality ethanol-resistant fuel line
• High-Quality Special-Application Heavy-Duty Stainless Fuel Line Clamps (with rounded edges and no slots to cut the line)
• A Round File to enlarge the hole on the gas tank for the Pingle Petcock (using a round file makes this simple and pulls shavings out of the gas tank, leaving none inside)
• Full-colour instructions and technical support

The process

The process of converting to gravity feed is simple and straightforward, and the provided instructions should be easy to understand and follow. However, there are a few things to keep in mind:

• You will need to vent the tank.
• You will switch to reserve a little sooner (about a quarter of a gallon sooner).
• You may need to adjust the float and run some sea foam in the tank to clean up any junk in the fuel system.
• Ensure that the tank has very good venting.
• Consider using the Grizzly float needle & seat if you're doing any performance riding.
• You can remove the filters off the petcock and the carburettor inlet tube and run only one filter for the gravity feed.
• You may need to raise the float level.

Replacing the fuel pump

The fuel pump on a Yamaha RoadStar can fail at any time, leaving you stranded. This is a guide on how to replace the fuel pump.

Step 1: Purchase a Fuel Pump Kit

Firstly, you will need to purchase a fuel pump kit for your Yamaha RoadStar. There are a variety of kits available online, such as the No Fuel Pump Mod Kit, which includes everything you need to remove the fuel pump.

Step 2: Prepare the Motorcycle

Park your motorcycle on a flat surface and engage the parking brake. Ensure the engine is switched off and the keys removed. Place a rag underneath the fuel tank to catch any spilled fuel.

Step 3: Remove the Fuel Tank

Locate and remove the bolts securing the fuel tank in place. Carefully lift the fuel tank away from the motorcycle, taking care not to spill any fuel.

Step 4: Access the Fuel Pump

The fuel pump is located under the seat, inside the fuel tank. You may need to remove additional components, such as the air box, to access the fuel pump.

Step 5: Disconnect the Fuel Pump

Disconnect the fuel lines and electrical connectors from the fuel pump. You may need to remove the fuel pump bracket to gain access to all the connections. Take note of the routing and orientation of the fuel lines to facilitate proper installation of the new fuel pump.

Step 6: Install the New Fuel Pump

Install the new fuel pump in the same location, ensuring all connections are secure and routed correctly. Reinstall the fuel pump bracket, if removed.

Step 7: Reinstall the Fuel Tank

Carefully lower the fuel tank back into position, ensuring it is securely mounted and all bolts are tightened.

Step 8: Final Checks

Check all fuel lines and electrical connections for leaks before starting the engine. Ensure the fuel tank is vented correctly. Start the engine and check for proper operation of the fuel system.

By following these steps, you can replace the fuel pump on your Yamaha RoadStar, ensuring reliable fuel delivery and preventing potential failures. Always refer to the motorcycle's service manual for additional information and safety precautions.

Relocating the fuel pump

The fuel pump on a Yamaha Road Star is located under the left side of the tank. It can be relocated to a hidden position under the right-side cover to massively de-clutter the left side of the engine and show off the cylinders.

There are a few ways to go about this. One way is to buy a fuel pump relocation kit, which includes all the necessary hardware, special brackets, and easy-to-follow instructions.

Another method is to completely remove the fuel pump and run the bike on gravity feed. This can be done on carburetted bikes but not on fuel-injected ones, as the fuel needs to be pressurised. If you do choose to remove the fuel pump entirely, you will need to make sure you have the proper petcock situation to avoid fuel starvation.

If you want to keep the fuel pump but move it to a different location, you will need to find a smaller one that fits in the desired spot. You will also need to make sure that the new location is pressurised and has a return line to the tank to avoid fuel starvation and burst lines.

Before attempting any of these modifications, make sure you have the necessary skills and knowledge to do so safely and effectively. Always refer to reliable sources for instructions and proceed with caution.

Troubleshooting fuel pump issues

Diagnosing the Issue:

• Check for power at the harness: Ensure that there is power at the connector or harness for the fuel pump. This can be done using a voltage tester or a multimeter.
• Check the fuel pump relay: The fuel pump relay is a common source of fuel pump issues. Check if the relay is faulty or needs replacement.
• Inspect fuses: Make sure all fuses related to the fuel system are intact and functional. A blown fuse could be the reason the fuel pump isn't working.
• Verify fuel supply: Ensure that the fuel tank is filled with sufficient fuel. Sometimes, a simple issue like an empty tank can cause fuel pump-related problems.

Testing and Jump-Starting the Fuel Pump:

• Disconnect the fuel pressure line: To test the fuel pump, disconnect the quick-connect fuel pressure line under the left side scoop that leads to the fuel pressure regulator.
• Jump-start the fuel pump: With the pressure line disconnected, jump-start the pump to see if it's working. If the pump is functional, fuel should eject from the disconnected line.

Fuel Pump Removal and Replacement:

• Safety first: Before performing any work on your motorcycle, refer to the owner's manual and safety guidelines. Ensure the engine is off, and the bike is parked on a level surface. Wear safety gear, including gloves and eye protection.
• Accessing the fuel pump: The fuel pump on a Yamaha Roadstar is typically located inside the fuel tank, under the seat. Refer to the service manual or seek guidance from a qualified mechanic to safely access and remove the fuel pump.
• Disconnecting fuel lines: Before removing the fuel pump, carefully disconnect the fuel lines leading to and from the pump. Place a rag underneath to catch any spilled fuel.
• Replacing the fuel pump: If the fuel pump is faulty, replace it with a suitable replacement part. Ensure that the new pump is compatible with your motorcycle's fuel system. Follow the installation instructions provided with the new fuel pump.

Considerations for Removing the Fuel Pump:

• Carbureted vs. fuel-injected systems: It's important to note that removing the fuel pump is generally feasible on carbureted engines, but not on fuel-injected systems. Fuel-injected engines require pressurized fuel, so simply removing the pump without modifications may not work.
• Fuel delivery and tank capacity: Removing the fuel pump may impact the fuel delivery system and the usable capacity of the fuel tank. The orientation and location of the pump play a role in ensuring adequate fuel supply.
• Fuel pressure and return lines: If you plan to relocate the fuel pump or switch to a carbureted system, ensure that you manage fuel pressure and return lines appropriately. Consult a professional mechanic or a detailed guide for such modifications.

Frequently asked questions