After yet another test ride where I had fuel pouring out of the overflow on the carbs, I decided that I was done trying to diagnose an intermittent problem in the stock fuel system on my PC800. Yes, it has finally become time to install the fuel injection system that I have been working on for several years.
The first course of action was to install the high pressure fuel pump I bought off ebay from a 2010 Honda Fury. After some modification to the PC800 plastics and relocating the wiring harness plugs, I was able to fit in the high pressure fuel pump.
Purists will not like how I had to cut part of the plastics out to make the pump just slightly visible from the outside. Then again, purists aren’t interested in fuel injecting a PC800.
With the trunk lid closed, a little bit of the fuel pump is visible. I can live with that.
I drilled through a spare PC800 fuel cap to make a return line for the high pressure fuel pump.
Some high temp RTV helps hold everything together. It isn’t a perfect or a pretty setup but I didn’t want to have to drop out the existing gas tank and put in the gas tank I modified several years ago. Maybe down the road I will do that but for now this works well.
High and low pressure lines routed up from the fuel pump. I should note that I do not have a low pressure boost pump installed at the moment although I think that I will end up having to put one in in order to access the lower half of the fuel tank. Testing will be needed before I can make that determination.
The Honda Fury throttle body and fuel injection intake manifold near the position where it will be once everything is installed. I am going to hang a UNIPOD or similar filter off the front of this. I still need to figure out where I can pull vacuum from on this setup for the secondary MAP sensor I am running to do on-the-fly altitude correction.
Top-down view. I am going to be using some wide diameter fuel hose with 90 degree bends pre-made to connect the injector intake body with the PC800 engine intakes. It isn’t the best way to do it but I don’t want to pay for a 3D printed metal intake adapter. Maybe down the road I will do that.
Here is a picture of the “brains” of the MicroSquirt that will be running the entire show.
More to come soon!