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Aftermarket Fuel pump fitment - Gen1 RSV1000

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ohmygewd View Drop Down
L Plates
L Plates


Joined: 21 Jan 2022
Location: Melb, Australia
Status: Offline
Points: 9
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    Posted: 21 Jan 2022 at 02:43
Hi All,

Very longtime lurker (even forgot my username)!!

I've had the Mille since new and it's been on stands for at least 6-8 years with 6mthly starts although l had been slack for the last 2 years and it was only when l went to start it this year, fuel leaked everywhere and while it cranked the pump was not priming.

So l emptied the tank with the varnish smelling fuel, pulled the fuel pump housing out and found all the inner vent lines persisted (hence the leak from the overflow) and the outlet hose to the filter practically off, tested the fuel pump and that was seized -the relay is operational and at least the wiring still in great condition!!

Purchased an all ball kit and found two issues:
- Pump body doesn't fit the housing due to a longer body.
- Kit came with no spacer.

After trying to do an extensive search on this, l thought can it be as simple as dremelling the top of the fuel pump plastic housing to accept the new pump, cut slits in order to clamp the fuel pump body to the housing and reuse the old rubber spacer (resembling playdo) as a spacer damper?

Any advice appreciated with last resort looking for a used OE fuel pump and housing.


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ohmygewd View Drop Down
L Plates
L Plates


Joined: 21 Jan 2022
Location: Melb, Australia
Status: Offline
Points: 9
Post Options Post Options   Thanks (0) Thanks(0)   Quote ohmygewd Quote  Post ReplyReply Direct Link To This Post Posted: 21 Jan 2022 at 02:56
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