This will run the fuel pump and drain the tank into the gas can. Continue to drain the tank until no more fuel flows. Disconnect the battery when the draining is completed. Remove the aluminum tray that holds the tank in place. With the tank empty, it will only drop an inch or so when the tray is removed. Remove the inner left rear wheel liner. The C6 feed hose consists of a double female 45 degree AN fitting, fuel filter, 15 inch AN hose and the 90 degree tapered fitting that screws into the tank.
The C5 hose is slightly different. The lines come preassembled for easy reference. Loosely attach the assembly to the pump as shown and put the assembly in the left fender well. The pump will mount to the frame with screws as far forward as you can get it. The aluminum brackets will line up nicely with the bottom of the frame rail and the bulkhead. The angles of the fuel line — filter assembly will show you where the pump will best fit.
The fuel line assembly should follow the contour of the tank and end up at the rear of the tank. Locate the spot where the 90 degree end will meet the tank with the line following the frame contours and mark it.
Make sure the spot is as low as possible on the back of the tank. Remove the pump assembly for now. You will be drilling a hole in the tank at this spot. The fitting is a tapered thread and will tighten up as it is screwed in. DO NOT use an electric or battery powered drill around fuel. Some fuel will definitely come from the hole, so be prepared with a pan or container to catch it.
Tap just deep enough so that the fitting will start in the hole. Besides, even at their best, the factory units of yesteryear pale in comparison to the high performance standards of today. So what are we waiting for? Starting with the disassembly, first remove your lines from the inlet and outlet of the fuel pump. Place a container underneath the pump to recover any spilled fuel, then plug or clamp off the lines if needed. The pump, held on by 2 bolts, should now be free and ready for removal.
Just to be on the safe side, I always recommend using new pipefittings on projects such as this one. If your new pump did not include them, they can be found at any hardware store. Keep in mind you will need fittings for the regulator as well. Install the proper fittings on the pump and regulator prior to installation. This gives you a little more room to ensure everything is tight and ready to go.
When reinstalling the pump, use a small screwdriver to carefully hold the pushrod up and out of the way. After cleaning the mounting surface of old gasket material, apply a small dab of sealer to the new gasket and reinstall the fuel pump. Getting the pump into place and making sure the pushrod is properly seated on the rocker can be a little tricky at times. The pushrod has a natural tendency to slide down inside the block, past the point of actuation.
If clearance allows, use a small screwdriver to retain the rod while backing the pump in see photo 1. However, this will only work with a cold motor. Insert a jumper wire into the fuse box terminals as shown. This will run the fuel pump and drain the tank into the gas can. Continue to drain the tank until no more fuel flows.
Disconnect the battery when the draining is completed. Remove the aluminum tray that holds the tank in place. With the tank empty, it will only drop an inch or so when the tray is removed. Remove the inner left rear wheel liner. Loosely attach the assembly to the pump as shown and put the assembly in the left fender well.
The pump will mount to the frame with self-tapping screws as far forward as you can get it. The aluminum brackets will line up nicely with the bottom and side of the frame. The angles of the fuel line — filter assembly will show you where the pump will best fit.
The fuel line assembly should follow the contour of the tank and end up at the inside rear corner of the tank. Locate the spot where the 90 degree end will meet the tank and mark it.
Make sure the spot is as low as possible on the back of the tank. Remove the pump assembly for now. You will be drilling a hole in the tank at this spot.
The fitting is a tapered thread and will tighten up as it is screwed in. DO NOT use an electric or battery powered drill around fuel. Some fuel will definitely come from the hole, so be prepared with a pan or container to catch it.
Tap just deep enough so that the fitting will start in the hole. This way the tapered fitting will get extremely tight as it goes into the hole. If you tap it too deep the hole will be too large.
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