2001 - 2007 Suzuki Hayabusa Fuel Pump Diagnosis and Replacement / Repair

Does your Fuel Injected bike have a loss of power or surging power? Does it have long cranks to fire up, particularly when it sits for a while? Then this video is for you! I dive into how these symptoms are caused by a fuel pump, some thing's I ruled out, how to pressure test the pump, and show you how to replace the pump on my 2003 Suzuki Hayabusa. This diagnostic process applies to nearly every fuel injected engine, and this repair process will apply to most Gen 1 Busas. Particularly 2001 - 2007 Busas. Come along for the ride while I tear into it and maybe learn a thing or two!
I did get a refund on my parts from Quantum Fuel Systems for creating this video, But I intended to do this repair anyway. I genuinely chose Quantum Fuel Systems product as my product through research.
I will post "official" final test results this coming riding season. Look out for that!
I also Have a video on how I ruled out the Throttle Position Sensor (TPS)!
• Gen 1 Suzuki Hayabusa ...

[@vincentagro3151]

wow my 2003 Suzuki hayabusa was also losing serious power. it sat for a long time and the cranks lasted an eternity. i tore the bike apart cylinder by cylinder looking for the problem to no avail. thanks to your video, i have now been able to correctly diagnose and fix my bike. very insightful, matt. i wouldn’t be able to ride without you. forever grateful.

[@mattzahmdotcom]

Thanks!!! Glad you're rolling again! Ride on!

[@joshuaanothereraseddad]

Good video chief. When using a compressor to blow out components like that just turn down the pressure. I've gone as low as 30psi for such jobs.

[@Gualdino1]

Used your video to replace my pump. Keep the good videos coming!

[@micjohnbenson]

Hey Matt. Really enjoyed your video, definitely top notch comparing with other similar videos on KZbin. If I may ask if you could explain the parts and also show them (closeup) to see how the part looks like and where they connect to. for example, the pressure regulator that you replaced. Keep up with the amazing effort buddy. Hayabusa greetings from Pretoria South Africa

[@mattzahmdotcom]

Thanks! Good idea. I should have done some close ups and included a parts comparison. I will do that in future videos for sure! Busa love from Buffalo, NY, US!

[@leomontaefeltus90]

Yeah cuz I zoomed in and I think that long and short wires I switch them on opposite sides cuz when I go to tap my shifter my pump wines again like I hit the kill switch and cranks but won’t start

[@belle_store]

Great video for help changing fuel pump and analysis symptom of break down fuel pump!

[@bdogjr7779]

Suzi sounds like she has a Turbo🔊I'm guessing it's just the acoustics of your garage👍👍👍

[@mattzahmdotcom]

Def the acoustics. My mics are kinda cheap too, for now at least. Turbo Busas are so cool. Been watching lots of @MooreMafia with his turbo GSXRs and his bro @bigkountry with his sweet turbo Busa. Love the boost!

[@bdogjr7779]

@@mattzahmdotcom 《☆》MooreMafia is cool. I like Brock's too🖖😎☮

[@ABunchOfBusas]

Turbo Busa 🏍

[@Drummerjeffkazee]

Great video brother 👍. Really appreciate your time to help everyone.

[@huskycd6]

great and informative video.

[@zzzpip]

cheers matt keep them coming pal.

[@cliffgarcia1393]

Hey Matt any know abouts with the fuel pump wire diagram I got the 4 prung harness on the bike an the fuel pump is 3 prung any thoughts been searching for days anything would help looking to splice an connect thanks Matt

[@llllll3147]

It would have been nice if you would’ve showed us how to take off the tank

[@fuzebox7190]

can you do a walk through of the assembly ? instead of fast forwarding it?

[@Busaguy]

Really great and easy to follow video. But how did you reuse the pump wires without cutting one end of the original connectors, so you can pass the wires through the original black plastic cover that slips over the nuts on fuel pump. Thanks!

[@mattzahmdotcom]

I don't believe I reused the cap. If I remember correctly the cap has a loose fit over the nuts. Not protecting it from fuel or anything. As long as the nuts/screws to the wires are tightened down properly there should be no issue. Hope it helps

[@philipgavin509]

Dude your videos have been a huge help but im having big issues and really need your help

[@mattzahmdotcom]

I can try. What's happenin?

[@MegaImmelman]

Hey I got a 1999 Hayabusa gen one that's giving me some of the same problems that you're replacing Parts with how do I contact you to see if you can do some work on it

[@martincorvalan8704]

hi mate - quickquestion. You went through a start up process when reconnecting the battery - what was that?

[@mattzahmdotcom]

It's been a while since I shot this. But it looks like I sort of did things out of order there. I reconnected the battery before I finished bolting up the tank, and was checking and refitting connections below it. But, I cycled the ignition a few times to prime the pump and fuel lines. When you disassemble the fuel system it drains and fills the system with air. There will still be air in there, but cycling the pump a few times pressurizes and fills the lines back up. It reduces cranking time when firing back up from fuel sys service. It looks like it even stalled after the initial start which would have been due to an air pocket. Hope this is what you were referring to and is helpful.

[@luisrivera8322]

la recomiendo ,la compre la misma en ebay ,la motora tiene mas pode, no tube problema de la intalacion todo a original.mi moto hayabusa 2007,lo unico adicional fue limpiar el tanque con vinagure y ponerle sellador.

[@mattzahmdotcom]

¡Excelente!

[@brandonsparks9980]

What’s goin on man, could you by chance post the link to the fuel pump assembly you used? Thank you!

[@cbrhurrican]

Hey guys, I just recently purchased one.. It's a 05 model, after a changed sparks oil and filters, new coolant.. Taken for a test drive and realized white smoke out from exhaust (oem) not all the time... . Bike strats and runs fine got 25k miles... What can be the problem? Please any advice 🙏

[@mattzahmdotcom]

I'm sorry but I cannot give much quality advice without diving into the bike with my hands on it. I do know that white smoke typically means burning coolant (steam). Generally speaking, black smoke means the engine is running rich(too much fuel). Blueish smoke means burning oil. White smoke is a tally steam from infiltration of coolant into the cylinder. The blue smoke from burning oil can look whitish, if not sure smell will tell. Coolant will smell weird, kind of like a sweet smell. I wish you the best of luck.

[@donsimpson1976]

hello Matt can you tell me if the replacement pump motor was the same size as the OEM

[@mattzahmdotcom]

I shoulda held the two together for the video, that woulda been a great idea. Ahhh, hindsight. But the Quantum pump was the same size. They looked almost identical, minus the colors/materials used. Fitment was near perfect. Only note here I could think of would be: when inserting the pump back in the assembly, I pressed it in all the way. I then installed the retainer and had a bit of gap between the pump and retainer. I simply slid the pump to the retainer. The fuel pressure would do this in the tank anyway. But I just wanted to know it was seated against the retainer with a good seal to the assembly. And it was. That might be too much info. But it should make sense when you have the assembly in your hands. Hope this helps!

[@donsimpson1976]

@@mattzahmdotcom thank you,I'm looking to replace the pump in my 05 busa and clean or replace the fuel injectors

[@mattzahmdotcom]

@Don Simpson fresh fuel system, nice! Plenty of room to attack the injectors with the tank off for the pump. Chasing problems or maintenance?

[@donsimpson1976]

@@mattzahmdotcom just some Maintenance I think the pump my be alittle weak and may as well clean the injection system too can't hurt lol

[@Hal-ug2jr]

Hey Matt, great video, I'm about to tear into my 2004 Busa as I'm having the same problems at high RMP's, power drops off around 9,500 or so, I can coax it a bit with playing with the throttle. Did this fix your problem? I'm thinking on changing it anyway, over 160K km on the bike (100k miles), I've owned her from day one off the showroom floor, love this bike. Cheers!

[@mattzahmdotcom]

My problem was very similar. But without hands on your bike, I can't be certain. I've been seeing issues with clogged fuel filters on high milage busas as well. So I'd look into possibly bypassing the filter. I've seen some forum posts on how to do that. I hope you got her back running tip top again. Lmk what worked for you.

[@Malosti]

My bike randomly jerks for a second and runs fine when I twist the throttle at around 6k rpm on a 02 gsxr 1000 I wonder if it’s my fuel pump

[@mattzahmdotcom]

Hard to say. Surging throttle response could also be a symptom of a bad pump. It could also feel like the engine is hitting a ceiling if the pump just can't keep the pressure up enough to meet the high flow at higher rpm.

[@marcellusallen9675]

The orb at 5:47 bottom left Lol! Boo! 😂😱

[@824718717]

Hi! My 2004 Busa is displaying C41 code error, I’ve checked the fuses, fuel pump relay and they look good. Any idea what could be the problem?

[@mattzahmdotcom]

Hard to say. Could be a number of things. Does the bike run? Also, would have to know how you tested the relay. Could be clicking but still resistance at the through contacts within. Could be an open or a short in the wires or the pump. I really would need to be hands on to help.

[@Andrei_K1G1K]

Having the same sort of issue with my 2001 Gixxer 1000. Did this solve your issue?

[@mattzahmdotcom]

Yes. For me the fuel pump did the trick

[@fromtheslumsofbethlehem2743]

Hey great video. My bike tipped over in the drive very minor ! But my issue started from this, and I’m having that same issue losing power up top. What do you think? No issues ever with the bike before this!

[@mattzahmdotcom]

It could very well be the pump. Can't say definitively without getting my hands on her. But if she's older, it's not uncommon for the pumps to get tired.

[@caseycohen8407]

Great video, i have a 05 and the bike sat for 2 + yrs, now the bike just cuts off. I rode it and it died on me. Do you rhink its the pump? Thx

[@mattzahmdotcom]

Hard to say to be honest. If it's a bad pump, symptoms would most likely be a no start, or lack of power with increased rpm. It would really depend on the conditions when the bike dies. Was it fine then died and wouldn't start? I've heard of bad kickstand switches causing the bike to turn off mid ride. But that's sorta a shot in the dark

[@brandonsparks9980]

Did you go with the high flow fuel pump from quantum or the OEM replacement?

[@mattzahmdotcom]

You only need high flow for high power applications. Like boost or big bore or something that would make the engine to require larger fuel injectors to supply more fuel. If you're running stock injectors you should be fine with OEM type replacement. I would like to note, I ran into trouble with the quantum pump a bit after this video. I ended up going with a Fuel Pump Factory replacement and that one has been strong for over a year now and many hard passes down the drag strip.

[@Bostonn617]

@@mattzahmdotcomwhere did you get the factory replacement and how much was it? I’ve heard mixed reviews on the quantum and a lot of people saying it’s super loud compared to OEM

[@85jordanboi23]

2 questions for you. When I looked on quantum 1 review said that the fuel pressure regulator didn’t fit correctly, did you have any issues or have to trim it? And also do you have the part number they had like 4 different ones on the website. Thank you

[@mattzahmdotcom]

Hey I'm sorry for delayed reply. I had no problem with the quantum regulator. It fit perfectly. I wish I did a parts comparison for the video too. (I haven't done many, still learning). But from what I remember they looked the same, and was a direct fit. The part number is HFP-PR34. That fit my 03 Busa.

[@justinlawson4374]

I was looking for the relay because the fuel pump won't turn on and it's not the fuse

[@mattzahmdotcom]

It's under the rear plastic, below the seat, on the left side. Right next the the battery, but on the outside of the frame. Hope this helps.

[@L4ND.SH4RK]

👏👏👏👏👏👏👍

[@bdogjr7779]

Awesome Matt《☆》Nice work with diagnostics & results👍I had to replay 2wice I was making dinner. Did you see any rusty spots in your tank. I saw a clump of rust in the bottom of my tank but I couldn't see where it came from looking thru the filler🗣Quantum sounds like a good choice. Maybe Global warming will send You an early thaw🖖😎☮

[@mattzahmdotcom]

I'm pretty lucky. It was very clean in there for it's age. Only a bit of crud in the strainer, and when I flushed the filter it came out tinted but not dark and cleared up quickly. So all in all it seemed pretty clean. Can't wait to test ride it to confirm the results!

[@leomontaefeltus90]

Ona busa u don’t have to pull in the clutch as u start

[@mattzahmdotcom]

Ah. Just a habit from some of my other/previous bikes

[@ABunchOfBusas]

On my Gen 1 and gen 2 Busa I have to pull the clutch in to start. My Gen 3 Busa I don't have to pull it in. Just make sure it's in neutral. I don't know what Busa you have but that's not always the case for Busas. Busa 🏍!

[@mwenyezislot8601]

A quantum fuel pump ?? Lol let me know how long your problem was fixes for they are ass