Replacing Fuel Pump In Suzuki Boulevard C50: Step-By-Step Guide

The Suzuki Boulevard C50 is a popular motorcycle model, and like any vehicle, it requires regular maintenance to keep it running smoothly. One such maintenance task is replacing the fuel pump, which is responsible for supplying fuel from the tank to the engine. While it may seem like a daunting task, replacing the fuel pump on a Suzuki Boulevard C50 is a relatively straightforward process that can be completed in a few hours with the right tools and knowledge. This article will provide a step-by-step guide on how to replace the fuel pump on a Suzuki Boulevard C50, covering everything from removing the old pump to installing the new one, and offering tips and tricks to make the process easier.

Removing the tank

To remove the tank, you will need to first remove the seats. Use a 6mm allen head to remove the bolt for the rear seat and two bolts for the front seat. Next, use a 3mm allen bolt to remove the three bolts holding the dash in place. Flip the dash over and pull back the dust boot to reveal the wiring harness. Disconnect the wiring harness by squeezing the clip.

Now, you will need to remove the tank itself. There is a 12mm bolt at the end of the tank that needs to be removed. Pull the tank up and back a few inches to free it from the mounts. Place a rag or towel over the frame where the seat was to protect the paint from the sharp edge of the tank.

Disconnecting the fuel pump

With the tank removed, you can now disconnect the fuel pump. Flip the tank upright and squeeze the clip on the brown connector to unplug the wiring harness. Then, squeeze the grey prongs to remove the quick-connect on the fuel line.

Removing the fuel pump

To remove the fuel pump, you will need to remove the bolts holding it in place. Remove the bolts in a cross-hatch pattern a little at a time to avoid warping the baseplate.

Installing the new fuel pump

When installing the new fuel pump, be sure to use a new o-ring and apply grease to the o-ring channel. Tighten the bolts in a cross-hatch pattern and in three steps to 88-inch/pounds using a torque wrench.

Reassembling the bike

Once the new fuel pump is installed, you can reassemble the bike. Put the tank back on, resting the back edge where the seat goes. Plug in the quick-connect and the brown wiring plug, then lower the tank back into place. Reinstall the bolt at the end of the tank and replace the seats and dash. Reset the clock and refill the tank.

Disconnecting the wiring harness

Step 1: Before you begin, make sure you have the necessary tools, including a set of Allen keys and a torque wrench.

Step 2: Remove the rear seat by unscrewing the bolt that holds it in place. This will give you access to the fuel tank.

Step 3: Locate the three 3mm Allen bolts that secure the dash in place. Remove these bolts and set the dash aside.

Step 4: Flip the dash over and locate the wiring harness. It is connected to the dash by a plug with a clip. To disconnect the wiring harness, carefully squeeze the clip and unplug it from the dash.

Step 5: With the wiring harness disconnected, you can now access the fuel tank. Loosen the bolt at the end of the tank and carefully lift it up and back to free it from the mounts.

Step 6: Place a rag or towel over the frame to protect the paint from any scratches that may occur when handling the fuel tank.

Step 7: Now that the fuel tank is accessible, locate the brown connector on the wiring harness. Squeeze the clip on the connector to unplug the wiring harness from the fuel tank.

By following these steps, you will have successfully disconnected the wiring harness, allowing you to proceed with the next steps in replacing the fuel pump on your Suzuki Boulevard C50. Remember to work carefully and consult a professional if you have any doubts or concerns.

Disconnecting the fuel line

Step 1:

Locate the fuel line. It is connected to the fuel pump, which is usually mounted on the fuel tank.

Step 2:

Before you begin, place a rag or towel over the frame where the seat was to protect the paint from any scratches.

Step 3:

To disconnect the fuel line, first squeeze the clip on the brown connector to unplug the wiring harness.

Step 4:

Next, squeeze the grey prongs to release the quick-connect on the fuel line. This will free the fuel line from the fuel pump.

Step 5:

Now that the fuel line is disconnected, carefully move the fuel tank and set it aside, ensuring you don't spill any fuel.

Step 6:

With the fuel tank removed, you can access the fuel pump for replacement. It is important to work in a well-ventilated area and wear protective gear when handling fuel.

Step 7:

Before removing the old fuel pump, remember to drain the remaining fuel from the tank to avoid spills.

Step 8:

Once the tank is drained, proceed to remove the bolts holding the fuel pump using the appropriate tools, following the manufacturer's instructions or a repair manual for torque specifications.

Step 9:

When reinstalling the new fuel pump, ensure you use a new O-ring and apply grease to the O-ring channel. This will help create a tight seal and prevent fuel leaks.

Step 10:

Tighten the bolts securely, following a cross-hatch pattern and using a torque wrench to achieve the specified torque.

Step 11:

After installing the new fuel pump, reconnect the fuel line by attaching it to the fuel pump and securing it with the quick-connect fitting.

Step 12:

Finally, reattach the wiring harness by plugging it into the corresponding connector. Ensure it is securely connected.

Remember to work carefully and follow all safety precautions when working with fuel. If you're unsure about any steps, it's always best to consult a qualified mechanic or refer to a repair manual specific to your Suzuki Boulevard C50 model.

Removing the fuel pump

Step 1: Remove the seats

Remove the rear seat by unscrewing the single bolt that holds it in place. Do the same for the front seat, which is held in place by two bolts. All three bolts are 6mm allen head bolts.

Step 2: Remove the dash

Remove the dash by unscrewing the three 3mm allen bolts that hold it in place. Flip the dash over and pull back the dust boot to reveal the wiring harness. Squeeze the clip and unplug the harness.

Step 3: Remove the fuel tank

Locate the 12mm bolt at the end of the tank and unscrew it. Carefully pull the tank up and back, freeing it from the mounts. Place a rag or towel over the frame where the seat was to protect the paint from the sharp edge of the tank.

Step 4: Disconnect the fuel tank wiring and fuel line

Flip the tank upright. Squeeze the clip on the brown connector to unplug the wiring harness. Then, squeeze the grey prongs to remove the quick-connect on the fuel line.

Step 5: Remove the fuel pump

Turn the tank over and remove the bolts holding the fuel pump in place. Do this in a cross-hatch pattern, a little at a time, to avoid warping the baseplate.

Step 6: Install the new fuel pump

Place a new o-ring on the new pump, using a small amount of grease in the o-ring channel. Apply threadlocker to the pump mounting bolts and bolt the new pump into place. Tighten the bolts in three steps, using a torque wrench to achieve 88-inch/pounds of torque.

Step 7: Reassemble the bike

Put the tank back on, resting the back edge where the seat goes. Plug in the quick-connect and the brown wiring plug, then lower the tank back into place. Reinstall the bolt at the end of the tank. Reinstall the driver and passenger seats, as well as the dash. Push the dust cover back into place after plugging in the dash. Finally, 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 that is compatible with your Suzuki Boulevard C50. It is important to use a fuel pump that is designed for your specific motorcycle model. You will also need a new O-ring, as it is not advisable to reuse the old one. Apply a small amount of grease to the O-ring channel of the new fuel pump, and have some thread locker ready for the pump mounting bolts.

Step 2: Remove the Old Fuel Pump

Start by removing the rear seat with a 6mm Allen wrench. Then, remove the front seat with the same tool. With the seats removed, you will have access to the fuel tank. Next, remove the 3mm Allen bolts that hold the dash in place and flip it over to access the wiring harness. Disconnect the wiring harness by squeezing the clip and unplugging it.

Now, you can proceed to remove the fuel tank. Loosen the 12mm bolt at the end of the tank and carefully lift it 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 scratches. Once the tank is removed, flip it upright and disconnect the brown wiring connector and the fuel line.

With the fuel tank removed, you can now access the old fuel pump. Remove the bolts holding the fuel pump in a cross-hatch pattern, loosening them a little at a time to avoid warping the baseplate. Take your time with this step to ensure that you do not damage the surrounding components.

Step 3: Install the New Fuel Pump

With the old fuel pump removed, it's now time to install the new one. First, apply a new O-ring to the fuel pump, ensuring that it is properly seated in the channel. Then, mount the new fuel pump onto the fuel tank using the provided bolts. Tighten the bolts in a cross-hatch pattern and in three steps to 88-inch/pounds, using a torque wrench.

Step 4: Reassemble the Motorcycle

Now that the new fuel pump is installed, it's time to put everything back together. Reattach the fuel line and the brown wiring connector to the fuel tank. Carefully lower the tank back into place and secure it with the bolt you removed earlier. Reinstall the driver and passenger seats, as well as the dash. Don't forget to push the dust cover back into place after plugging in the dash. Finally, reset the clock and refill the fuel tank.

Your Suzuki Boulevard C50 should now be ready to ride with its new fuel pump! Remember to always refer to the motorcycle's service manual for detailed instructions and safety precautions when performing any maintenance or repairs.

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