Vulcan 900 Fuel Pump Problems: Revealed & Fixed [Guide]

| |

Hey there, fellow motorcycle riders! We all know that our beloved Vulcan 900 is a true beast on the road, but like any machine, it can sometimes face hiccups with its fuel pump. Fear not, for we’re here to help you identify those pesky fuel pump problems and guide you through some nifty solutions to revitalize your ride. Let’s hit the throttle and embark on this journey to problem-free riding together!

What’s Up with Vulcan 900’s Fuel Pump?

Our Vulcan 900, despite being a powerhouse, can encounter some common fuel pump issues. We’re talking about stuff like the fuel pump refusing to play ball despite receiving electricity, the mystery of the elusive inline fuse, and clogged petcocks messing with our precious gas flow.

Key Takeaways

  • Common fuel pump problems in the Vulcan 900 include non – functionality despite receiving electricity, lack of information about the inline fuse, and clogged petcocks that affect gas flow.
  • To fix these issues, you can start by testing and troubleshooting electrical connections, checking for inline fuses and replacing them if necessary, and cleaning or replacing clogged petcocks.
  • Additionally, following a DIY fuel pump and strainer service guide can help resolve any remaining fuel pump problems in the Vulcan 900.

The Mystery of the Non-Functional Fuel Pump

Picture this: you’ve got all the juice flowing through the wires, but the fuel pump sits there like a stubborn teenager, refusing to come to life. This electrical enigma can really throw us off our smooth rides. Sure, we’ve checked the ignition fuse, replaced it even, but nada! Still no action from the fuel pump.

It turns out that sneaky culprits like dirt and grime clogging vital parts or excessive heat can play spoilsport, leaving our bikes powerless and us scratching our heads.

The Elusive Inline Fuse

Ah, the dreaded inline fuse! Many Vulcan 900 riders find themselves scratching their helmets when faced with a non-functional fuel pump despite all the electrical power. Why? Because they weren’t clued in about the existence and significance of the inline fuse for the fuel pump.

This little fuse is a guardian, protecting our precious fuel pump from electrical overloads. But without knowing about its existence, we’re left in the dark, wondering why the pump won’t play nice with all that power.

Petcocks and Gas Flow Woes

Ever experienced poor performance or your bike refusing to start? Well, a clogged petcock could be the mischievous culprit. The petcock controls the flow of gas to the engine, and if it’s clogged, it’s like putting a kink in the fuel supply hose.

To get things back on track, we need to get hands-on, either cleaning that pesky petcock or swapping it out for a shiny new one. Clear that gas flow, and your Vulcan 900 will be roaring to go again.

Solutions to Unleash Your Vulcan 900’s Fuel Pump

Now that we’ve decoded the issues, it’s time to fire up those wrenches and bring our rides back to life!

Testing and Troubleshooting Electrical Connections

Let’s kick things off by ensuring those electrical connections are in top-notch shape. Grab a multimeter and follow these steps:

  1. Check for power at the fuel pump connector.
  2. Inspect the wiring harness for any damage or loose connections.
  3. Test the fuel pump relay by swapping it with a known working relay.
  4. Check that ground connection for any corrosion or poor contact.
  5. Verify that there are no blown fuses related to the fuel pump circuit.

Hunting for the Elusive Inline Fuse

Don’t let that inline fuse keep playing hide-and-seek with you. Take matters into your own hands:

  1. Get to know where that inline fuse hides.
  2. Check it out for any signs of a blown fuse, and replace it if necessary.
  3. This little guy might be the key to getting your fuel pump back on track.

Dealing with Clogged Petcocks

The gas flow struggle ends here! Follow these steps to tame that clogged petcock:

  1. Locate the petcock near the fuel tank.
  2. Turn off the fuel supply and disconnect hoses.
  3. Remove the petcock and give it a good clean with some carburetor cleaner.
  4. If cleaning doesn’t work, consider a petcock replacement.

A DIY Fuel Pump and Strainer Service Guide

For the brave souls who want to dive even deeper, here’s a step-by-step guide:

  1. Disconnect the negative battery cable for safety.
  2. Remove that fuel tank with care.
  3. Spot the fuel pump assembly and disconnect all electrical connections and fuel lines.
  4. Unscrew the mounting bolts securing the pump assembly.
  5. Lift out the fuel pump and inspect the strainer for damage or clogs.
  6. Clean or replace the strainer as needed.
  7. Check the fuel pump for any leaks or wiring issues.
  8. Replace with a compatible new fuel pump if required.
  9. Reassemble everything, making sure everything’s snug and secure.
  10. Refuel, reconnect, and get ready to hit the road.


So there you have it, motorcycle enthusiasts! Fuel pump problems in our Vulcan 900s don’t stand a chance against our newfound knowledge and DIY skills. Let’s diagnose, fix, and ride with confidence!


How can I tell if my Vulcan 900 is experiencing fuel pump problems?

Keep an eye out for trouble starting the engine, random stalling or misfires, decreased fuel efficiency, and that weird whining noise from the fuel tank.

How can I figure out if my Vulcan 900’s fuel pump is faulty?

Test it out by checking fuel pressure with a gauge, inspecting wiring and connectors for damage or corrosion, and listening for unusual noises when turning the ignition on.

What causes fuel pump issues in Vulcan 900?

Clogged or dirty filters, electrical faults, weak battery or alternator, and general wear and tear are among the possible culprits.

Can I fix my Vulcan 900’s faulty fuel pump myself?

While it’s doable, we recommend consulting an experienced technician for proper diagnosis and safe repair procedures. Safety first, folks!


Are Harleys Reliable? Yes and No (You Won’t Guess Why)

Suzuki Boulevard C50 Fuel Pump Problems: Fixed [Guide]


Leave a Comment