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Old 09-25-2012, 12:52 PM   #1
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ATV: 2004 650 v-twin
2004 650 V2 fuel pump problem

Has anyone had their fuel pump fail on a 2004 650 V2? I only have 254 hrs on this machine. It has been babied.
I have power to the plug but the fuel pump will not run. Is there anything I could be missing with this.
If I do need to replace the pump could anyone recommend where to find one? The dealer price is $692. The dealer said he has never heard on one going bad. PLEASE HELP

I am new to this site.
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Old 09-25-2012, 01:37 PM   #2
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ATV: 2005 650 V2
2010 Mileage: 200
2009 Mileage: 350
2008 Mileage: 300
2007 Mileage: 100
2006 Mileage: 30
I haven't heard of a V2 pump going bad either. I was thinking the fuse but you have power. You need to pull it out and see what it looks like. Might be somethink simple, you just never know.

254 miles in 8 years. 32mi/year That's not nearly enough, heck it's probably only had a few tanks of gas in its entire life. The V2's are way to fun not to get out and "feel the need for speed"
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Old 09-25-2012, 04:49 PM   #3
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You didn't drive it enough, it's paying you back.


Take it apart, it's easier with the rear plastics removed. I'm sure you could find a cheap pump that would work just as well, and could even put it in line and attach it to the frame somewhere. No reason whatsoever to pay that much for a fuel pump.
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Old 09-25-2012, 09:47 PM   #4
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ATV: 2004 650 v-twin
650 v2 fuel pump

A friend and I tested the fuel pump. It was only putting out a little less than 2psi. It looks like the actual pump on the assembly can be replaced. I am waiting to here from a seller on e-bay to see of the pressure is correct (2.6 - 3.3 psi). If it is a good replacement it will have saved $400!
Thanks for the replies.
Yes I do need to ride more
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Old 09-25-2012, 09:51 PM   #5
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Thanks. I may have found the actual pump can be replaced and not the entire assembly. Saving $400 hopefully
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Old 09-26-2012, 12:42 PM   #6
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Keep us updated, Mkenel.
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650 V2

Teryx Gear Reduction, 4.0 Differentials
Highlifter 31 Outlaws, Snorkels
Ammo Cans, Back Rest, Tunes
MTI 1.5" Lift Kit and Arched Arms
Dynatek CDI, Temp Gauge
VFJ Stage II Primary
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Old 09-27-2012, 07:48 AM   #7
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ATV: 2004 650 v-twin
04 650 v2 fuel pump

The pump I found on e-bay is for an 05 kawasaki brute force 750.
NO luck with this pump. Seems no one can tell me what the psi range is on the pump. I spent yesterday going to and calling dealers trying to get psi info on the this pump.
The fuel pump assembly is a kawasaki pump (part#49040-1076). This part # is obsolete.
After I pulled the fuel pump assembly and bench tested it (a little less than 2psi) it was discovered that the "pump" can be "removed from the assembly. The "pump" is made by mitsubishi.
This pump on e-bay is from (the seller) "Hit the Gas". The part number he has listed is "FF304". It is from McDonald ATV. McDonald ATV shows the part # "FF304" as kawasaki part #49040 0005. Again no one can tell me the psi range for this. I went to a kawaski dealer and had the parts guy look up this part# (49040 0005). His diagram showed a completed different pump. AAAARG
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Old 09-27-2012, 07:53 AM   #8
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ATV: 2004 650 v-twin
04 650 vs fuel pump

I ordered the entire fuel pump assembly for $561.00. I am going to our anual ride on Drummond Island in 2 weeks. Good thing I found this problem when I did. This just made my trip that much more expensive.
Seems pretty rediculous the price of this pump assembly when the actual pump could be replaced.
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