| 
I
 made a few paper templates to figure the smallest area I could cut out 
and still fit the pump, sump and fuel level sender. I ended up with this
 rectangle. I drilled out the corners, then cut the panel out with a 
sabre saw (it did not blow up). Then I drilled out the welds holding on 
the sender mounting ring and the breather tube.  | |
| 
The
 Honda tank is not a simple box, like the Roadster's, so I cut into it 
with a cold chisel (it did not blow up) to get at the catch can and the 
complex pump mounting ring (not shown), which I did not use in the end, 
although most
 do. If you buy the correct tank, you will not see this catch can, but 
what follows is how I modified. First I cut off the mounting tabs so 
that it would sit flat on the bottom of the tank. | |
| 
Then,
 after many fitment tests, I mounted it to one of the baffles with a 
very large sheet metal screw. A wide fender washer distributes the 
squeeze of the screw on the plastic wall of the catch can.  | |
| 
Between the catch can and the baffle is a piece of 1" x 3/4" aluminum channel; it serves as a spacer.  | |
| 
As
 mentioned above, the stock Honda pump assembly held the pump too high 
above the tank bottom for my tastes, so I modified it by cutting the 
base of the bracket away. Click on the thumb to see before and after.  | |
| 
With
 the bracket modified, I could now adjust the height of the pump, and 
made it so it kisses the bottom of the catch can. The pump is very 
firmly held by the hose clamp. After this photograph, I replaced the 
orange rubber with a short section of radiator hose and turned the hose 
clamp to face down to improve ease of installation.  | |
| 
If
 you modify the pump to sit lower as I have, be sure to use in-tank EFI 
fuel hose for your new, slightly longer hose between the pump and the 
outlet tubing. Regular EFI hose WILL FAIL, sometimes quite quickly. The 
hose made by Gates, as a 5/16" side, in 12" lengths. It is Gates 
#42195185 or #27093 (Napa #H209).  | 
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Tuesday, September 6, 2011
Fuel Pump Installation - 
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