Pump and filters.

[Snapey]

I had a HP filter in pieces at one stage but decided to attempt a repair. No point having a filter that will only block up again so I left the HP filter out & drilled the bypass hole. I fusion welded the top and body together by heating a bit of sheet metal, melting the filter surfaces then putting them together. As soon as the surfaces touch they stick so get it right first time. Pressure test, no leaks, done.

That filter is now in the bike with an external filter and the perfectly good one I took out is in a box with my spares. Of course it's quicker to just drill the bypass hole but I'm happy I could get this filter working again.

[insane1400]

@Snapey  "I'm happy I could get this filter working again."
I bet you're even happier you didnt give suzuki $400+ for a new one 

[GSXKING]

Managed a quick jaunt on the bike, 50 k's out and 50 k's back (as per our new Covid-19 ease of restrictions).
Engine is 'crisper' in operation. Very easy and smooth through acceleration.
For a bike that is 13 years old just short of 100,000k's it seems, to me, to operate as if relatively new.
Just the benefits of regular maintenance and good mods. 

Just about run in I'd say @SheepDog 

[Nick]

Looking to the future, after having to buy the suzuki filter and pump unit. If I get any trouble again going to do the same as you. Sheep Dog. Did you get the barbed ends on your filter, what clips did you use to secure the pipes and can you clean them.
Thanks nick.

[SheepDog]

Hey Nick
You should get long usage out of your new Suzuki filter and pump.
The Aeroflow product I used had 5/16" barbs (Aeroflow - AF 610-05S) for compatibility with existing fuel line connectors on the bike (suffice to say the fuel hose I used was 5/16" type to connect between outlets). The hose clamps I used were EFI specific flat clamps that don't pinch the hoses. Picture below. You mechanics can attest to the history of leaking radiator hose from fatigue, vibration, and pinching of rubber hoses. Not to keen on having a leaking fuel line pissing fuel under pressure around my bike.



As for cleaning the external filter, here in Queensland we have this fluid called XXXX. Does a good job of cleaning out your pipes but I prefer to use a well aged single malt scotch. 

[froudy]

Not to keen on having a leaking fuel line pissing fuel under pressure around my bike.

Believe me when I say they piss out an awful lot of fuel VERY quickly! When I rebuilt by bike a few years ago I forgot to connect the fuel line and went to start the bike. As the pump tried to prime I was soaked in fuel within a second or two before I managed to turn ignition off.