Fixing Loud fuel pump ticking in gl1200


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Fixing Loud fuel pump ticking in gl1200

Postby virgilmobile » Thu Sep 29, 2011 9:43 am



My pump can be heard at 60 MPH.Tick..Tick..Not only a bit annoying,but a sign of impending failure?

I read about pumps shorting out and having blown fuses. A $60 pump at Autozone fixes this problem.

I just had to find out WHY.I checked first and Autozone has one in stock,just in case I fail :D
DISCLAIMER:although I was successful,this is for information ONLY.In my opinion a loud ticking pump MAY stop at any time and blow the fuse.

Here's the results in a nutshell...A sound dampening ring inside deteriorates,crumbles apart and lodges under the plunger,this stops the pump from cycling the switch and it just sits there,finally blowing the fuse.The coil measures about 3 ohms normally. Here's some pictures and my repair.

After reassembly I tested it and found that the new dampener ring was about .010" too thick.I had to bend the switch control arm to allow it to cycle on and off.A minor glitch but successful none the less.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby WingAdmin » Thu Sep 29, 2011 10:12 am

Excellent! A simple and cheap fix, my favorite type!
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Re: Fixing Loud fuel pump ticking in gl1200

Postby virgilmobile » Fri Sep 30, 2011 9:19 am

Update on the electric pump repair......I started the bike after the other repairs(water pump and timing belts)..I couldn't hear the pump at all :shock: ...I checked the electric..it was OK..now what :?: ..As I lay my hand on it (not in a magical kind of way,I'm running low on pixie dust) I could feel it thump once in a while ;) ..I actually had to use a stethoscope to hear it operate :D ...
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Re: Fixing Loud fuel pump ticking in gl1200

Postby hondavidson » Sun Oct 09, 2011 3:36 pm

So if I take jumper wires directly from the battery to the pump should I hear anything to let me know whether the pump is bad or not? I thought I heard one faint click but nothing after that.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby virgilmobile » Mon Oct 10, 2011 8:17 am

Yes.Connect 2 wires direct to the pump wires.Green ground,black 12 volt.Unless the pump is pressured up,It should start thumping.With no fuel,mine will cycle about 4 times a second.As soon as it gets fuel the cycling slows to a stop as soon as it gets to 3 psi fuel pressure.

Unhook the fuel line to the carbs and turn OFF the fuel.Test the pump.If it doesn't cycle , then pull the rear cap and look at the switch contacts.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby dkcloud » Fri Feb 24, 2012 1:02 am

When my fuel pump went out, I replaced it with that small electronic pump from Autozone.
That lasted a couple of months and it also failed.
I mounted the pump where the OEM pump was and I believe that was the problem.
I went back to Autozone and bought a fuel pump for a ford fiesta and mounted off the engine because I was afraid the engine heat was affecting the life of the electronic pump.
The new pump mounted with a single circle clamp.
It has been a year and no problems as of yet.
I was also able to put a metal inline fuel filter under the faux tank and suspend it off of the engine block to keep the fuel cool.
I live in South Texas and heat can become a problem, so far I have not had anymore problems.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby maniacmechanic » Tue Aug 21, 2012 12:05 am

[quote][/
After reassembly I tested it and found that the new dampener ring was about .010" too thick.I had to bend the switch control arm to allow it to cycle on and off.A minor glitch but successful none the less.

Read more: posting.php?mode=reply&f=12&t=8642&sid=b429f844835dd3a136cd4225d4090ff1#ixzz249IX4lOvquote]
Your picture shows a piece of hose that is .150 thick...should it have been .140? Would an O-Ring work? What diameter hose did you use? Thanks for the help.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby virgilmobile » Tue Aug 21, 2012 8:09 am

Actually any piece of rubber will work as long as it stays tight in the cavity.
I think what I used was a 1/4" fuel line.the hole needs to be larger than the shaft.
And yes,0.14" would have been best.with a bushing at 0.15" ,I had problems getting the pump to trip the switch.I had to "tweak" it just a little.
This was just a experiment that turned out good.
Feel free to change anything you like.
By the way, it still works perfectly.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby maniacmechanic » Sun Sep 02, 2012 3:49 pm

Repaired my pump the other day. Solenoid was very hard to remove from pump. Kinda scarry clamping pump end in vise tight enough to remove the solenoid, a little hard on the chrome as well, but can be done. Original dampner was made of a wax like substance and not in that bad of shape. I replaced it with a piece of 1/4" vacuum hose .140 in length. Reasembled pump. Quieter but not perfect. Dissassembled pump again and went with a .150 length. Worked fine, quiet as a church mouse. No arm adjustment necessary. So basically a very easy, very inexpensive fix that just requires a little playing to make work for each pump. MANY THANKS TO VIRGILMOBILE !!!!!!
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Re: Fixing Loud fuel pump ticking in gl1200

Postby steve allen » Wed Oct 02, 2013 7:16 pm

Can anyone tell me what fuel pump for "Ford Fiesta" was used? I am having issues with my pump, and the one I got for "Honda Prelude" is awful big to fit. I like the size of Ford Fiesta pump better.
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Re: Fixing Loud fuel pump ticking in gl1200

Postby steve allen » Wed Oct 02, 2013 7:17 pm

dkcloud wrote:When my fuel pump went out, I replaced it with that small electronic pump from Autozone.
That lasted a couple of months and it also failed.
I mounted the pump where the OEM pump was and I believe that was the problem.
I went back to Autozone and bought a fuel pump for a ford fiesta and mounted off the engine because I was afraid the engine heat was affecting the life of the electronic pump.
The new pump mounted with a single circle clamp.
It has been a year and no problems as of yet.
I was also able to put a metal inline fuel filter under the faux tank and suspend it off of the engine block to keep the fuel cool.
I live in South Texas and heat can become a problem, so far I have not had anymore problems.

What part number was used for Ford Fiesta fuel pump?


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