P500 P500 Fuel Pump Replacement

[KyGal83]

My fuel pump recently gave out my P5 on a ride at Windrock. The replacement has arrived, I am getting prepped to replace it hopefully next week. I have found a few threads here on how to do it. I was hoping for a video but no luck as of yet. Any advice for a complete mechanical novice before I get started? ... or should I just let the dealership install?

Yes, I am aware not to smoke near the gas tank. I'm not a smoker.

 

[NTCPrezJB]

My fuel pump recently gave out my P5 on a ride at Windrock. The replacement has arrived, I am getting prepped to replace it hopefully next week . I have found a few threads here on how to do it. I was hoping for a video but no luck as of yet. Any advice for a complete mechanical novice before I get started? ... or should I just let the dealership install?

Yes, I am aware not to smoke near the gas tank. I'm not a smoker.

A push pin tool and possibly some replacement push pins would be helpful for the effort getting to the tank.

An impact screwdriver (one you tap with a hammer not the power tool) with a proper size JIS bit might come in handy as well.

Take pics as you disassemble and put fasteners in labeled bags or a sort tray. That usually helps things go back together smoothly especially if the process gets interrupted.

I’m sure if you run into questions as you go there are several that would jump on a call with you to help you sort it out. As STGB says…it’s just nuts and bolts. You got this!💪🏻

 

[Hib]

Not too difficult at all. Had mine out and back in after couple hours without breaking a sweat. Bought a special tool for $20 that is suppose to release the retaining ring? on top but they won't work on the 500 cause it sits too close under the frame. A screw driver and hammer worked ok. Releasing the the connector on line was a PIA, will work.but little patience or the right tool

 

[Tom_C]

I've read, but can't confirm, it's the same engine as the foreman 500. Here is a vid for an EFI foreman.

 

[futzin]

My fuel pump recently gave out my P5 on a ride at Windrock. The replacement has arrived, I am getting prepped to replace it hopefully next week. I have found a few threads here on how to do it. I was hoping for a video but no luck as of yet. Any advice for a complete mechanical novice before I get started? ... or should I just let the dealership install?

Yes, I am aware not to smoke near the gas tank. I'm not a smoker.

What day are you looking at? I'll try to get there.

 

[Backwoods]

What day are you looking at? I'll try to get there.

Your a great and helpful person

 

[futzin]

Your a great and helpful person

. . . and a rotten mechanic! I can hold a flashlight and hand her drinky things.

She's got this; hell, she did her own Torq locker install!

 

[Backwoods]

. . . and a rotten mechanic! I can hold a flashlight and hand her drinky things.

She's got this; hell, she did her own Torq locker install!

I’m proud of her. She’s seems to have grit and determination.

 

[futzin]

I’m proud of her. She’s seems to have grit and determination.

Oh, hell yeah!

 

[906UP]

@KyGal83 you should be able to download the shop manual as a lifetime member.....I think. @futzin has my new phone number, if you run into any issues give me a call, I can walk you through it

 

[KyGal83]

@KyGal83 you should be able to download the shop manual as a lifetime member.....I think. @futzin has my new phone number, if you run into any issues give me a call, I can walk you through it

Thank you. I appreciate that very much. Be ready I’m sure I will need to call! 🤣

 

[KyGal83]

Oh, hell yeah!

I’m proud of her. She’s seems to have grit and determination.

Thank you. But get to know me.. you will see how absolutely untrue that is. 😆

 

[futzin]

It is indeed true. We all lose sight of the big picture sometimes . . . 😉

 

[Smitty335]

Thank you. But get to know me.. you will see how absolutely untrue that is. 😆

It would be nice / cool if you would do a step by step with pictures?

 

[KyGal83]

It would be nice / cool if you would do a step by step with pictures?

I will try my best to remember to do that.

 

[KyGal83]

A push pin tool and possibly some replacement push pins would be helpful for the effort getting to the tank.

Ordering thanks!

An impact screwdriver (one you tap with a hammer not the power tool) with a proper size JIS bit might come in handy as well.

Ummm.. What?

 

[KyGal83]

@KyGal83 you should be able to download the shop manual as a lifetime member.....I think. @futzin has my new phone number, if you run into any issues give me a call, I can walk you through it

Where do I find the shop manual to download? I used the search function and came up with nothing.

 

[NTCPrezJB]

Ordering thanks!


Ummm.. What?

Impact screwdriver…

https://www.amazon.com/DURATECH-Reversible-Screwdriver-Fasteners-organized/dp/B0B24LVVZN/?tag=sxsweb24-20

I didn’t pay attention to the listing to see if it had JIS or “Phillips” technically I think it’s supposed to be called “Robertson” bits with this particular one but that is the basic tool I was suggesting. JIS “Phillip” bits have more sharp angles on them whereas the Robertson version are more rounded.

If memory serves anyway. I’m sure Mr Go Ogle or someone that cares more than me could get you the absolute correct answer. Just know the Honda fasteners are JIS and will be less likely to strip if you use a JIS bit on them.

 

[906UP]

Where do I find the shop manual to download? I used the search function and came up with nothing.

https://hondasxs.com/threads/honda-sxs-service-manuals-500-700-1000-talon.34567/

 

[KyGal83]

https://hondasxs.com/threads/honda-sxs-service-manuals-500-700-1000-talon.34567/

Thanks! That is a huge help.