Replacing The Fuel Pump In Your 1999 Honda Shadow 1100

The fuel pump on a 1999 Honda Shadow 1100 is located in front of the swingarm and mounted to the airbox. While it is possible to access the fuel pump without removing the rear wheel and swingarm, it is a tight fit and requires some one-handed work. There are alternative methods to reach the fuel pump, such as removing the battery and battery holder or relocating the pump to a more accessible area. It is also worth noting that the fuel pump on the Honda Shadow is not a standard fuel pump but an automatic shut-off valve to prevent fuel flow in the event of an accident.

Removing the rear wheel and swing arm

To remove the rear wheel and swing arm of a 1999 Honda Shadow 1100, you will need to follow these steps:

First, locate the battery box and carefully remove it, making sure to take note of how it was positioned so you can put it back correctly later. Next, you will need to remove the right-side toolbox cover and the tools inside. This will give you access to the fuel filter, which is located in front of the rear wheel and swing arm.

Now, you will need to remove the clamps from the fuel hoses connected to the filter. These clamps have tabs, and you will need a pair of pliers to remove them. Work the clamps around carefully and slowly, as the hoses are tight. Once the clamps are off, carefully twist and turn the hoses to remove them from the filter. Be gentle, as the hoses are rubber and can tear if you use too much force.

With the hoses removed, you can now take out the fuel filter from its rubber holder. There may be a small piece of foam above the filter, so be careful not to lose it. Now, you have access to the swing arm and rear wheel. You can carefully remove them, making sure to keep track of all the parts and hardware for reassembly.

This process is quite challenging, and you may need to use some force to remove certain parts. It is recommended to have some mechanical knowledge or experience before attempting this. Additionally, having small hands and the right tools, such as long needle-nose pliers, can make the process easier.

Accessing the pump from under the bike

To access the fuel pump from under your 1999 Honda Shadow 1100, you will need to lay down and reach up under the bike, in front of the rear wheel. This method is possible but challenging, as it requires a lot of one-handed work and maneuvering in a tight space.

Before beginning, turn off the fuel at the petcock. Then, to access the pump, start by removing the battery box and the right-side toolbox cover and tools. This will give you a better view of the pump's location. You will need long needle-nose pliers to reach and remove the clamps on the rubber hoses connected to the pump. Work the clamps around and carefully pull the hoses off the pump. The outlet hose clamp, in particular, may be oriented upwards, making it more difficult to access from underneath the bike.

Once the hoses are removed, push the pump out of its rubber holder. You may need to bend and maneuver the hoses out of your way to access the pump fully. When reinstalling the new pump, be conscious of the orientation of the hose clamps to avoid leaks.

Alternatively, some Honda Shadow owners have found it easier to access the pump by removing the exhaust and side panels. This provides better visibility and access to the pump, making it a more straightforward process.

Relocating the pump to the toolkit pocket

To relocate the fuel pump of your 1999 Honda Shadow 1100 to the toolkit pocket, you will need to purchase a new fuel pump that is compatible with your motorcycle. You can find fuel pumps designed for the Honda Shadow 1100 online, through retailers such as Amazon or eBay.

Once you have acquired a new fuel pump, you can begin the process of relocating it to the toolkit pocket by following these steps:

Step 1: Remove the seat of your motorcycle to access the toolkit pocket. This will be the new location for your fuel pump.

Step 2: Disconnect the wires and fuel lines connected to the existing fuel pump. Be sure to have a container ready to catch any fuel that may spill during this process.

Step 3: Carefully remove the old fuel pump from its current location, taking note of how it is mounted and the routing of the fuel lines.

Step 4: Clean the area around the old fuel pump mounting location, ensuring that any dirt or debris is removed.

Step 5: Measure the dimensions of the new fuel pump and create a mounting bracket or plate that will secure it in place within the toolkit pocket. You may need to drill holes or make adjustments to the pocket to accommodate the pump and its mounting hardware.

Step 6: Mount the new fuel pump onto the bracket or plate and secure it firmly within the toolkit pocket. Ensure that the pump is stable and does not move around.

Step 7: Connect the fuel lines from the tank to the new fuel pump, following the same routing as before. Ensure that all connections are secure and tight to prevent leaks.

Step 8: Reconnect the electrical wires to the new fuel pump, ensuring they are properly attached and insulated.

Step 9: Prime the new fuel pump by activating the ignition and allowing the motorcycle to run for a few minutes. Check for any signs of leaks around the pump, fuel lines, or connections.

Step 10: Reinstall the seat, ensuring that it fits securely and does not put pressure on the fuel pump or its connections.

By following these steps, you will have successfully relocated the fuel pump of your 1999 Honda Shadow 1100 to the toolkit pocket, making it more accessible for future maintenance or repairs.

Removing the rear exhaust header

To remove the rear exhaust header of your 1999 Honda Shadow 1100, you'll need to follow these steps:

Firstly, place the bike on its side stand to provide a stable base for your work. Next, you'll need to remove the right-side toolbox cover and the tools within it. This will give you visual access to the fuel filter.

Now, you'll need to remove the clip from the right-side hose of the fuel filter. This can be tricky, so take your time and use long-nose pliers if necessary. Work the hose around and off the filter. You may need to use a flat bar to help get the hose off. Once the right side is free, carefully bend the hose out of your way.

Repeat the process for the left side, removing the clip and working the hose off. Now, push the filter out of its rubber holder. You may find a small piece of dense foam above the filter, which you can also remove.

At this point, you've successfully removed the rear exhaust header and can now install a new fuel filter. Insert the new filter from the right side, ensuring the larger side of the filter goes in first. Reattach the hoses and clamps, being mindful of the clamp placement on the rubber lines to avoid any leaks.

Finally, turn the fuel back on at the petcock, and you're done!

Removing the air filter box

To remove the air filter box from your 1999 Honda Shadow 1100, you'll first need to place the bike on its side stand. Then, follow these steps:

Step 1: Remove the Battery Box

• This step will give you better access to the area where the air filter box is located.
• Take a picture of the battery box before removing it, as it can be tricky to get it back in the correct position.
• Carefully twist, turn, push, and pull the battery box out.

Step 2: Access the Air Filter Box

• With the bike on its side stand, get down and look from underneath the bike, in front of the rear wheel.
• You should be able to see the air filter box located in front of the swingarm.
• If you can't reach it, try sliding under the bike and looking up towards the front of the swingarm.

Step 3: Loosen the Air Filter Box

• Identify the rubber hose clamps on both sides of the air filter box.
• Using long needle-nose pliers, carefully work the hose clamps around and remove them from the air filter box.
• Be prepared for some challenging one-handed work and manoeuvring in tight spaces.

Step 4: Remove the Air Filter Box

• Once the hose clamps are removed, carefully twist and bend the hoses out of the way.
• Gently push or pull the air filter box out of its rubber holder.
• Take note of any foam or other materials above the air filter box and set them aside for reinstallation.

Now that you've removed the air filter box, you can proceed with the next steps in changing the fuel pump on your 1999 Honda Shadow 1100. Remember to refer to a repair manual or seek assistance from a qualified mechanic if you need further guidance.

Frequently asked questions