Replacing Fuel Pump In Suzuki Vs700: Step-By-Step Guide

If you're looking to replace the fuel pump on your 1986 Suzuki VS700, there are a few things you should know. Firstly, it's important to determine whether your fuel pump has a separate relay, as some models have a 2-wire pump with a separate relay to operate it. Secondly, when choosing a replacement fuel pump, make sure to select one that is compatible with your specific bike model and year. You can refer to online forums and product specifications to ensure you're getting the right part. Once you have the correct fuel pump, you can follow the steps outlined in online tutorials or seek the help of a professional mechanic. Keep in mind that fuel pump replacement may require additional adjustments, such as syncing the carbs and checking for leaks.

Purchase a new fuel pump

When purchasing a new fuel pump for your 1986 Suzuki VS700, it is important to buy one that is compatible with your vehicle. Make sure to check the model and year of your Suzuki VS700 before purchasing a new fuel pump to ensure a proper fit.

There are several options available on Amazon and eBay for fuel pumps compatible with the 1986 Suzuki VS700. When considering which fuel pump to purchase, it is important to read reviews and compare prices to ensure you are getting a quality product.

• The AHL Fuel Pump for Suzuki Intruder 700 VS700 1986-1987 is made of high-quality metallic material and has good self-priming properties to ensure proper lubrication of the engine. It is a direct OEM replacement and is designed for motorcycles.
• The Areyourshop Fuel Pump is designed for Suzuki VS700, VS750, and VS800 Intruder models from 1986 to 2009. It is a brand-new starter, not a remanufactured or refurbished one, and is engineered to perform just like the original starter in your vehicle.
• The labwork Motorcycle Fuel Pump Replacement for Suzuki VS700, VS750, and VS800 Intruder 1986-2009 is another option that comes with a 4-wire plug.
• The Fuel Pump for Suzuki VS700, VS750, and VS800 Intruder is also compatible with your 1986 Suzuki VS700. It replaces OE # 15100-38A10 and has a 4-wire plug.

When purchasing a new fuel pump, it is important to consider the quality, compatibility, and reviews of the product to ensure a proper fit and reliable performance.

Check the number of wires on your old fuel pump

To replace the fuel pump on a 1986 Suzuki VS700, it is important to check the number of wires on your old fuel pump. This is because some Suzuki VS700 fuel pumps have two wires, while others have four.

To check the number of wires, simply locate the fuel pump in your vehicle and count the wires attached to it. This is important because, when purchasing a replacement fuel pump, you need to ensure you buy one with the correct number of wires.

You can find fuel pumps with the correct number of wires for your 1986 Suzuki VS700 on Amazon. For example, the labwork Motorcycle Fuel Pump Replacement for the Suzuki VS700 is specified as having four wires. Meanwhile, the Fuel Pump for Suzuki VS700 VS750 Intruder VS800 has two wires.

It is important to be aware that installing a fuel pump with the incorrect number of wires could be dangerous and may cause damage to your vehicle. Always consult a qualified mechanic if you are unsure about any aspect of replacing your fuel pump.

Check the fuel pump relay

To check the fuel pump relay on your 1986 Suzuki VS700, you'll need to locate and remove the relay, before testing it with a multimeter. Here's a step-by-step guide:

Locate and Remove the Fuel Pump Relay:

• Turn off your Suzuki's engine and remove the key from the ignition.
• Find the fuse box, usually located under the hood near the front of the vehicle, or under the steering column.
• Pull the cover off the fuse box and consult the diagram to identify the fuel pump relay, which is typically green or grey.
• Pull the relay straight out of the fuse box by its sides. If it's stuck, try rocking it gently back and forth.

Test the Fuel Pump Relay:

• Clean the relay prongs with a wire brush to remove any rust or corrosion. You can also use an electrical contact cleaner on a cloth for stubborn residue.
• Read the circuit diagram on the relay to identify the prongs that control the power. Typically, these are labelled 85 and 86.
• Set your multimeter to the ohm setting (Ω) to test the relay's resistance.
• Attach jumper wires to the positive and negative terminals of your Suzuki's battery.
• Connect one jumper wire to the negative relay terminal (usually labelled 85) and the other to the positive terminal (usually 86).
• Listen for a clicking sound when you attach the second wire. If you don't hear a click, the internal circuit may be faulty.
• Touch the end of the jumper wire to the prong repeatedly to listen for the click before clipping it back on.
• Hold the multimeter probes against the remaining two prongs on the relay, typically labelled 30 and 87.
• Check the multimeter reading. If it shows zero or a very small decimal, the relay is functioning correctly. If the reading is greater than zero, the relay circuit is faulty.

If your relay is functioning correctly, the issue may lie elsewhere in your fuel pump or electrical system.

Disconnect the negative battery cable

Disconnecting the negative battery cable is a crucial step when working on your Suzuki VS700's fuel pump, and it's important to do it safely and correctly. Here's a detailed guide on how to do just that:

Locate the Battery

First, you need to find the battery. It's usually bolted in place under the hood. If you haven't raised the hood of your Suzuki VS700 before, refer to the owner's manual to locate the hood release mechanism and the safety catch.

Locate the Positive and Negative Terminals

This step is crucial. Identify the positive and negative terminals on the battery. The positive terminal is marked with a "+" sign, while the negative terminal is marked with a "-". Sometimes, these terminals have plastic caps that you'll need to remove to access the battery cables and cable clamps.

Gather the Right Tools

You'll need some wrenches to loosen the battery cable clamps. Most battery cable clamps have 10-millimeter bolts, so a 10-millimeter open-end wrench or a socket wrench of the same size will come in handy. You may also need an adjustable open-end wrench in some cases.

Unbolt the Negative Cable

Make sure the ignition is off before you begin. It is recommended to wear eye protection for this step. Loosen the nut on the negative terminal with the appropriate wrench by turning it counterclockwise. Then, carefully remove the negative cable by lifting it away from the battery. Be cautious not to let the wrench touch both the negative and positive terminals simultaneously. Even a dead battery may have residual electricity, which could create a spark or damage your vehicle's electrical system.

Move the Negative Cable Away

Once the negative cable is disconnected, push it aside and ensure it's well out of the way. It's crucial to prevent any accidental contact with the battery.

Unbolt the Positive Cable

Now, repeat the same process for the positive cable. Loosen the nut with the wrench and remove the positive cable. Again, be cautious to avoid any contact with the negative terminal.

By following these steps, you will have successfully disconnected the negative battery cable, along with the positive cable, ensuring a safe working environment as you proceed with replacing the fuel pump on your 1986 Suzuki VS700.

Drain the fuel from the tank

To drain the fuel from the tank of your 1986 Suzuki VS700, you will need to first locate the fuel pump relay, which is attached to the underside of the rear seat. The fuel pump on the Suzuki VS700 has four wires: Y/G, Br/B, O/W, and B/Y. The Br/B wire goes to the pump, along with a B/W wire. The O/W wire is for battery power via the fuse box, the Y/G wire comes from the start button, and the B/Y wire comes from the igniter and coil.

Before draining the fuel tank, it is important to turn off the fuel pump relay to prevent any accidental activation of the pump during the draining process. This can usually be done by locating the fuse box and removing the fuse for the fuel pump circuit.

Next, you will need to locate the fuel tank drain plug, which is typically located at the bottom of the fuel tank. Place a suitable container underneath the drain plug to collect the drained fuel. Once you have located the drain plug, loosen and remove it using the appropriate tool, such as a wrench or a drain plug socket. Allow the fuel to drain completely from the tank.

After draining the fuel tank, it is important to properly dispose of the drained fuel. Do not pour the fuel down the drain or into the ground, as it can contaminate the environment. Instead, store the drained fuel in a safe container and dispose of it at a designated fuel disposal facility or recycling center.

Finally, before refilling the fuel tank and reinstalling the drain plug, it is recommended to clean the inside of the fuel tank to remove any debris or contaminants. This can be done by using a fuel tank cleaning solution and a soft cloth or brush. Ensure that the fuel tank is completely dry before refilling it with fresh fuel.

Frequently asked questions