Hey guys and gals, just wanted to throw out some information I had to figure out the hard way. I was doing a frame up restore on my fiance's 650R and managed to drop the gas tank as I was putting her back together. Ruined the paint job I had just sprayed and it broke the stupid plastic piece... Against all advice I prepared a ******* fix and JB welded the sucker back together. This lasted about 5 minutes. Went back to the drawing board and considered tapping the base plate. After about 2 hours of wandering around Home Depot and Ace hardware I decided to try out a copper fitting by tapping the base plate and threading the replacement parts directly into the metal base plate of the fuel pump. I used a 1/4 nipple with a 1/4" to 1/8" reducing 90 and threaded a rubber hose adapter into the 90. I believe the tap was a 5/16 or 3/8s cant remember right now. So after removing the plastic piece with channel locks on those torx heads, I very slowly tapped the base plate. No drilling was required but the tap could only move about an 1/8 of a turn before I had to turn back to clear the cuttings. This created a bit of a mess in the pump outlet line. I should have prefaced with a removed the pump before attempting this procedure. To clear the cuttings I took off the plastic piece on top of the fuel pump by squeezing with the same channel locks as before. Under this there is 2 clips holding the fuel pump solenoid/valve thingy. remove those and give a firm tug, with our bare hands on the silver solenoid piece. This gives direct access to the outlet line. I then flushed the line with water until all of the cuttings were removed. I then laid it out to dry. Once dry I threaded the nipple in tight then put the 90 and adapter on. I tried using the stock fuel line but found it kinked and the engine was running way to lean. I swapped the stock line with some hose from napa and doubled up the fuel line clamps on the adapter because I chose a fuel line that fit loosely over this piece. The size I chose fit snugly over the stock snap connector though. I then snaked the hose around the front of the bottom part of the air box. The hose I selected fit snugly over the stock fuel line piece that is attached to the throttle body. I simply slid the hose on and lightly tightened a clamp over the hose ( plastic piece once again). Started her up and she is running great... I actually forgot the plastic piece on the fuel pump that covers the fuel pump solenoid/valve piece. She seems to be riding better than before honestly but I have rebuilt the clutch, changed the oil, and had the bike down to frame since she was lasted started so it is hard to tell what caused the change in performance. I hope this helps the next person out before you spend 200 bucks on a new pump due to some cheap plastic bs. Feel free to hit me up if you want pictures or more instruction! Planned obsolescence pisses me off so I am happy to pass on the knowledge. Also, if you do not know what most of these words mean (parts tools etc) you may want to grab a mechanically inclined buddy. One last thing BE VERY CAREFUL WHILE TAPPING. This is soft metal and you can easily turn your thread right out as you cut. Tiny bit forward half a turn back every time. Good luck!
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