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illeak: Hello everyone. I am doing what another member asked me to do. I have recently had a fuel pump failure that Kawa refused to repair under warranty on a 4 onth old Teryx4. There are other threads about that whole situation. Anyway, I brought the broken machine home and was able to fix my machine. In the process I discovered what cause the fuel pump failure. I have water and sediment (mud) in my fuel tank which clogged my fuel pump filter. The check valve on the pressure line from the tank to the frame was stuck open from all the dirt/mud/debris inside it and the hose. And I do not submerge my machine. I ride trails and the occasional water/ mud hole. Nothing very deep and have never had water to my seats. Its my opinion that Kawa put the location of the hose way to low on the machine (it goes into the frame below the passenger seat). So I came up with a mod that moves the hose up into the center hub near the top of the motor. This mod moves the end of the hose up atleast 10-12 inches. It also puts an air filter on the end of it to help protect the fuel tank from outside contamination. I spent less than 20 dollars on parts for this mod. I bought three foot of rubber fuel line, 2hose clamps, a male to male hose connect and a small breather air filter.
So I removed the pressure hose from the tank and the frame. I then removed the frame part of the hose and added the fuel line I purchased with a hose clamp. I routed the fuel line with the actual fuel line from the tank. I then ran it up to the top of the motor and put the male to male connector and air filter on the end of the hose. I zip tied the air filter to another hose to secure it. I also shorten the small hose that comes out of the fuel tank by half an inch before the ninety degree turn before the check valve. I did this to lower the check valve closer to the tank. Hopefully the pictures help me explain what I did. I could of easily extended this hose to under the dash where the intake for the motor is but I did not want to remove the dash again. If you have any questions feel free to ask away. If you read this and see any changes that are needed please share. Hopefully this will get a sticky so that I can help people from having to go through what I have been throguh with KAWA this past week! Cause I am sure no one wants to give Kawa seve hundred dollars for a fuel pump!!!! :scared2:
Danny
The first three pictures are of the items I bought at advance auto parts fr less than twenty dollars.
The fourth picture is of the original way Kawa had the pressure/check valve hose was located.
The last four pictures show the new hose and how it was run. They also show the air filter on the end of the hose and how I mounted the hose/air filter.
illeak: Hello everyone. I am doing what another member asked me to do. I have recently had a fuel pump failure that Kawa refused to repair under warranty on a 4 onth old Teryx4. There are other threads about that whole situation. Anyway, I brought the broken machine home and was able to fix my machine. In the process I discovered what cause the fuel pump failure. I have water and sediment (mud) in my fuel tank which clogged my fuel pump filter. The check valve on the pressure line from the tank to the frame was stuck open from all the dirt/mud/debris inside it and the hose. And I do not submerge my machine. I ride trails and the occasional water/ mud hole. Nothing very deep and have never had water to my seats. Its my opinion that Kawa put the location of the hose way to low on the machine (it goes into the frame below the passenger seat). So I came up with a mod that moves the hose up into the center hub near the top of the motor. This mod moves the end of the hose up atleast 10-12 inches. It also puts an air filter on the end of it to help protect the fuel tank from outside contamination. I spent less than 20 dollars on parts for this mod. I bought three foot of rubber fuel line, 2hose clamps, a male to male hose connect and a small breather air filter. So I removed the pressure hose from the tank and the frame. I then removed the frame part of the hose and added the fuel line I purchased with a hose clamp. I routed the fuel line with the actual fuel line from the tank. I then ran it up to the top of the motor and put the male to male connector and air filter on the end of the hose. I zip tied the air filter to another hose to secure it. I also shorten the small hose that comes out of the fuel tank by half an inch before the ninety degree turn before the check valve. I did this to lower the check valve closer to the tank. Hopefully the pictures help me explain what I did. I could of easily extended this hose to under the dash where the intake for the motor is but I did not want to remove the dash again. If you have any questions feel free to ask away. If you read this and see any changes that are needed please share. Hopefully this will get a sticky so that I can help people from having to go through what I have been throguh with KAWA this past week! Cause I am sure no one wants to give Kawa seve hundred dollars for a fuel pump!!!! :scared2:
Danny
The first three pictures are of the items I bought at advance auto parts fr less than twenty dollars.
The fourth picture is of the original way Kawa had the pressure/check valve hose was located.
The last four pictures show the new hose and how it was run. They also show the air filter on the end of the hose and how I mounted the hose/air filter.
