Contributed by
John Hudson, aka GitSum, STOC #8086~~~
Fuel Pump Repair ( ST1100 )
Here is how I was able to revive my OEM pump.
I originally took it apart to just see how it worked, but the only thing wrong with it that I could find was that it was
pretty well "crudded up"
First of all - this is what the armature and magnets looked like once I pulled it apart! Geez, I wonder why it stopped working!
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%201.jpg)
I pulled the pump out of it's housing by removing the white nylon clip at the end.
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%202.jpg)
I used my trusty Dremel® tool to slice the case open. I also had to pry up the tabs that fold down over the end piece. Not a whole lot you can damage unless you go really deep with the Dremel®.
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%203.jpg)
Here are the pieces starting to come out (this is after I semi cleaned everything up and put the pieces back in place for the photo).
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%204.jpg)
Here are all the parts cleaned and ready to go. The white circular piece (top left) is actually the front part of the pump chamber. The large hole with the slot is where fuel flows in an get pushed out the circular hole which has a little nozzle on it. Look at the brushes - this pump ran for 100,000 miles and there is still plenty of material left.
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%205.jpg)
I put everything back and used that hose clamp to hold it together for now. I started sliding it back into the housing (it's actually a pretty tight fit) I just removed the hose clamp and slid it the rest of the way in. The slice in the casing didn't really seem to have any effect on the pump or it's performance.
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%206.jpg)
Here is a better picture of the components with the armature and magnets removed. The black impeller goes inside the housing directly above it and the armature has two 'forks' that fit into the two slots of the impeller. The larger nozzle on the left is for 'fuel out'.
(http://www.st-riders.net/aow/AOW%20-%20ST1100/Fuel%20Pump%20Repair%20-%20ST1100/Pic%207.jpg)
It is possible that the "guts" of the pump may slide out - but due to the wiring, I think it is going to have to all slide out in one direction. I really didn't expect to get the pump working again and the easiest way to take it apart was to cut it open. Actually, I don't think the cut really effects very much - the case may be just a hair bigger now but is contained by the housing. The armature rides in the synthetic end caps so it shouldn't be effected. I put a couple of thousand miles on it and ended up selling the bike.
~~~
Thank You again for your contribution
John Hudson, aka GitSum, STOC #8086