Brad The Bike Boy: 748 / 916 Replacement fuel pump - pick up extension required when using later style pumps

Saturday, July 4, 2026

748 / 916 Replacement fuel pump - pick up extension required when using later style pumps

I see a few pre 1999 model year 748 and 916 with running issues after the fuel pump has been replaced with a non original pump.

I checked the fuel pressure on one recently and it was 2 bar. Testing the pressure regulator showed it was letting go at 3, so it wasn't that. Pulling the pump showed the problem.

I went through this a few years ago and put a couple of videos on Youtube about it - the first in exasperated confusion (that bike had arrived from another shop after someone else had done the pump replacement), the second after I'd worked it out. That bike back then wouldn't pick up fuel at all. I've seen a few since with running issues or "It ran ok for a while, then played up" like this one, with exactly the same cause.

916 Fuel pump video 1

916 Fuel pump video 2

The OEM early 748 and all 916 fuel pump is a Walbro, with a long snout on the pick up side. See the first photo. People replace them with generic pumps that have no snout, as per the second photo. If you do that, you need to add the pick up extension piece to lower the fuel pick up level to just above the screen. And cut a little slot in the pump rubber to let the plastic bump stick out. The screen provides enough restriction to stop the pump sucking without it. Pick up extension: 48410291B, retaining clip 85040311A. These parts are from the parts catalogues of 1999 onward models - 996, 998, ST2/3/4, etc.

The other difference between the pumps is the wiring connector. The 916 era Walbro pump has two individual spade terminals, whereas the later pumps take a plastic connector with two spades inside.

I buy the replacement connectors, pull the original terminals out and then replace the terminals on the original wiring with the required 6.3mm female locking spade style and put them in the plastic connector. Make sure you get the polarity right - there are small + and - moulded onto the pump bodies. A pump spinning backwards moves no fuel.

For example:

Fuel pump connector

Fuel pump connector disassembled

6.3mm Female spade terminal with locking tab

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