Honda CRF450RL Fuel Pump Troubleshooting / How To Replace Or Repair

A friend of mine brought me his Honda CRF450RL with a "no start" condition. In this video I will show how to troubleshoot it a bit, and then what I had to do to fix it. Removal of the fuel pump, disassembly of the fuel pump assembly and things to look for. This fix was really simple, fortunately.
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[@blairguinea6811]

Nice job Tom

[@TomsTinkeringandAdventures]

Thank you!

[@JeahnLaffitte]

This was awesome, thank you. I suddenly had a stall that lasted about 1 second on the highway with my 450l so I’m trying to figure out what the issue might be!

[@TomsTinkeringandAdventures]

Hopefully you figure it out.

[@SuperiorTim989]

Mine has been acting up for the last 600 miles and finally crapped out yesterday. Some days it's completely fine and once in awhile it will shut off or spit and sputter. There is another channel called mob city moto that explains the symptoms he had with his. This is a great video as well. I would have just ordered a new one without looking at what it might be first. Now I can look the pump over and check for something like this.

[@TomsTinkeringandAdventures]

@@SuperiorTim989 I didn’t look into it, but you can likely just get the pump itself rather than the entire housing unit as well. Honda wants a lot for the entire thing, so just pulling it apart and replacing the pump is going to be considerably cheaper. Good luck.

[@SuperiorTim989]

@@TomsTinkeringandAdventures yes I just ordered a "all balls" rebuild kit for about 80$.

[@SuperiorTim989]

So it turned out mine was that same wire. Got it fixed and worked great for 200 miles worth of different trips here and there. Oddly enough I hit a small jump,landed and the bike died out. It won't start and I can't here the relay or the fuel pump. Would that mean the relay could be bad?

[@johnc5090]

My 2018 450r had nearly the same issue, except the ground wire was broken at the terminal closest to the connector. I did the same repair, except had to use a different pin on the 4 pin connector side as it had broken the first off completely. I suspect fuel slosh moves the wires and eventually fatigues the terminal. I put a zip tie on the wires to help prevent this happening again....

[@TomsTinkeringandAdventures]

@@johnc5090 my buddy tried to find just the wires, Honda doesn’t sell them. I guess it would be a good business opportunity.

[@williamdeslauriers9647]

Struggling with fuel pump is a major pain in the buttock on 2003 Chevy Malibu! It was some corrosion and a clogged fuel filter which caused a breakdown. 😞

[@TomsTinkeringandAdventures]

Yes, usually it’s not too difficult to troubleshoot at least.

[@mreddier9598]

If you know how to troubleshoot something like that, you don't have to walk 20 miles.

[@TomsTinkeringandAdventures]

I don’t like walking if I don’t have to.

[@blairguinea6811]

The thing is not everyone knows how to troubleshoot, infect some have got no idea.................and you are right

[@TomsTinkeringandAdventures]

@@blairguinea6811 true, that’s why it’s nice to ride with a buddy who does! 😂