Replacing Suzuki C50 Fuel Pump Sensors: A Step-By-Step Guide

If you're looking to replace the fuel pump sensors on your Suzuki C50, there are a few things you'll need to keep in mind. Firstly, it's important to determine the model year of your bike as the fuel pump assembly varies between years. For instance, the 2005, 2006, and 2007 models have different part numbers, and the fuel sender assembly differs based on whether the bike has a fuel gauge or not. Additionally, the wiring harness may differ between model years, so ensure you have the correct number of prongs for the fuel pump connection. When it comes to the replacement process, it is recommended to refer to a repair manual or seek guidance from a professional mechanic. However, some general steps include removing the seats, dash, and fuel tank, draining the gas, and carefully disconnecting and reconnecting the wiring harness and fuel lines. It is crucial to use a new O-ring and grease during reassembly, and proper torque specifications must be followed to avoid leaks.

Removing the tank

Begin by removing the seats. There is one bolt for the rear seat and two bolts for the front seat, all of which are 6mm allen head bolts. Loosen and remove these bolts and set the seats aside.

Next, you will need to remove the dash. There are three 3mm allen bolts holding it in place. Remove these bolts and carefully lift the dash off, being mindful of any wiring that may be connected to it. Once the dash is removed, you will have better access to the tank and other components.

Now, locate the wiring harness that is connected to the tank. This is usually covered by a dust boot. Remove the dust boot and carefully squeeze the clip to unplug the wiring harness. It is important to be gentle during this step to avoid damaging the clip or the wiring.

At the end of the tank, you will find a 12mm bolt. Remove this bolt, as it is holding the tank in place. Now, carefully lift the tank up and back, freeing it from its mounts. It is a good idea to place a rag or towel over the frame where the seat was to protect the paint from any sharp edges on the tank.

Once the tank is free, flip it upright and locate the brown connector. Squeeze the clip on this connector to unplug the wiring harness that is connected to the tank itself. There should also be a grey quick-connect on the fuel line; squeeze the prongs to remove this as well.

With these connections removed, you can now fully remove the tank from the Suzuki C50. It is important to drain the gas from the tank before proceeding with any further repairs or maintenance.

Reinstalling the tank is simply a matter of reversing the steps outlined above. Ensure that all connections are secure and that the tank is properly mounted before taking the Suzuki C50 out for a ride.

Disconnecting the wiring harness

Step 1: Remove the Seats

Start by removing the rear seat with a 6mm Allen bolt. Then, remove the front seat with two 6mm Allen bolts. This will give you access to the fuel tank and the wiring harness.

Step 2: Disconnect the Wiring Harness

Locate the wiring harness connected to the fuel pump. It is usually held in place with a clip. To disconnect it, carefully squeeze the clip and unplug the wiring harness. Make sure you don't pull on the wires themselves, as this can damage them.

Step 3: Release the Fuel Line

Before you can remove the fuel tank, you need to release the fuel line. Locate the quick-connect on the fuel line and carefully disconnect it. You may need to squeeze the gray prongs to release it. Place a rag or towel underneath to catch any spilled fuel.

Step 4: Remove the Fuel Tank

Now, you can remove the fuel tank by lifting it up and back to free it from the mounts. Be careful not to scratch the paint on the frame. Place the tank on a flat surface and flip it upside down.

Step 5: Disconnect the Fuel Pump Wiring Harness

On the underside of the fuel tank, you will find another wiring harness connected to the fuel pump. Squeeze the clip on the brown connector to unplug this wiring harness as well. Again, be gentle and only apply pressure to the clip, not the wires.

Step 6: Verify the Connections

Before proceeding, take a moment to verify that all wiring harnesses related to the fuel pump have been disconnected. This is important to ensure that you can safely remove the fuel pump without damaging any electrical connections.

Step 7: Prepare for Fuel Pump Replacement

Now that the wiring harnesses are disconnected, you can proceed with the rest of the fuel pump replacement process. This may include draining the fuel tank, removing the old fuel pump, and installing a new fuel pump with a new O-ring and threadlocker. Remember to refer to a reliable guide for the full fuel pump replacement procedure.

Remember to work carefully and wear appropriate safety gear when handling fuel and electrical components. If you're unsure about any steps, don't hesitate to consult a professional or seek additional guidance.

Removing the fuel pump

Step 1: Remove the rear seat by unscrewing the bolt with a 6mm allen head. Then, remove the front seat by unscrewing the two bolts with the same size allen head.

Step 2: Take out the three 3mm allen bolts to release the dash. Turn it over, pull back the dust boot, and squeeze the clip to unplug the wiring harness.

Step 3: Locate the 12mm bolt at the end of the tank and unscrew it. Carefully lift the tank up and back to free it from the mounts. It is important to place a rag or towel over the frame to protect the paint from any sharp edges on the tank.

Step 4: Flip the tank upright and squeeze the clip on the brown connector to unplug the wiring harness. Then, squeeze the grey prongs to detach the quick-connect on the fuel line.

Step 5: Remove the tank from the Suzuki C50. Drain the remaining gasoline from the tank and flip it over.

Step 6: Remove the bolts holding the fuel pump in a cross-hatch pattern, taking care to do it gradually to avoid warping the baseplate. It is important to note that you should not reuse the O-ring, and applying grease in the O-ring channel is essential.

Step 7: Install the new fuel pump by placing a new O-ring on it and using threadlocker on the mounting bolts. Tighten the bolts in a cross-hatch pattern, ensuring you follow the manufacturer's torque specifications.

Step 8: Reinstall the tank, ensuring the back edge is resting where the seat goes. Plug in the quick-connect and the brown wiring plug, and lower the tank back into place.

Step 9: Reattach the bolts, seats, and dash. Push the dust cover back into place, reset the clock, and refill the tank.

Installing the new fuel pump

Step 1: Prepare the New Fuel Pump

Before you begin, make sure you have a new fuel pump assembly with a new O-ring. Apply a small amount of grease to the O-ring channel, and ensure that the O-ring is properly seated in the groove of the new fuel pump. This will help create a tight seal and prevent fuel leaks.

Step 2: Mount the New Fuel Pump

Carefully position the new fuel pump onto the fuel tank, ensuring that it is properly aligned with the mounting holes. Start tightening the bolts in a cross-hatch pattern, a little at a time, to secure the fuel pump. Be sure to use a torque wrench and tighten the bolts in a few steps until they reach 88 inch-pounds of torque.

Step 3: Reinstall the Fuel Tank

Once the new fuel pump is securely mounted, carefully lower the fuel tank back into place. Reconnect the fuel line by attaching it to the quick-connect fitting. Also, reconnect the electrical connector by squeezing the brown wiring plug. Ensure that all connections are secure and tight to prevent any fuel leaks.

Step 4: Reassemble the Motorcycle

Now, carefully place the fuel tank back onto the motorcycle frame, ensuring it is properly positioned and secured. Reinstall the seats, dashboard, and any other components that were removed during the disassembly process. Ensure that all bolts and fasteners are tightened securely.

Step 5: Final Checks

Before starting the motorcycle, perform a final inspection to ensure that all connections are secure and there are no signs of fuel leaks. Check the fuel lines, electrical connectors, and the area around the fuel pump for any signs of leakage. Once you are satisfied that everything is secure and leak-free, you can start the motorcycle and test the new fuel pump.

Step 6: Test the Motorcycle

After starting the motorcycle, let it run for a few minutes to ensure that the new fuel pump is functioning properly. Check for any unusual noises or signs of fuel leaks. Take the motorcycle for a short ride to ensure that the fuel pump is working as expected and that there are no performance issues.

By following these steps, you can confidently install the new fuel pump on your Suzuki C50, ensuring a safe and reliable riding experience. Remember to refer to the motorcycle's service manual for additional information and always practice safety when working on your vehicle.

Reattaching the tank

To reattach the tank of your Suzuki C50, you can follow these steps:

• Ensure the fuel line is connected to the tank.
• Reattach the fuel line clip, which is usually gray.
• Reconnect the electrical connection for the fuel pump and fuel light.
• Place the tank back into position, ensuring the rubber pads are in place.
• Secure the tank with the bolt at the rear.
• Reinstall the speedometer or instrument cluster, ensuring the wires are connected.
• Refill the tank and start the bike to check for any leaks.

It is important to be careful when reattaching the tank to avoid damaging any components and to ensure all connections are secure to prevent leaks.

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