Well after almost 20 years my BG400 fuel pump gave up the ghost. I have not run it in about 2 years and now it pours fuel out between the motor and the body.

I did buy the Ninja rebuild kit last year just in case, so at least I'm not dead in the water with parts. Anyone one have any tips or do I just dive into the project?

Wow that sucks. My whole post with pictures disappeared. No wonder there aren’t tech posts with pictures on Moparts anymore.

Try again

I did one a few years ago & remember something about a special tool to take it apart. I don't remember exactly what it was. I think the bottom cover has some sort of tamper-proof screws holding it in place. Or something needed a special socket to remove some bolts.

I have the special tool (socket) for the bottom bolts but another special tool (Vice grips) work great too. Then just put in the same size bed head bolts when you put it back together. It saves time if rebuilding one at the track. There are two different BG400 pumps and both take different seal kits. One is more common than the other. The vanes should go back in position exactly how they came out. Just lay them out in order as they wear from rotation.

Thanks!

How did you get the insert out? Stupid me nicked a corner but that should be ok. I don't know how to get it out without breaking it.

Did you put anything on the seal? I was thinking a dab of Vaseline.

And I had a bunch of white powder and crystals. Is that from the fuel?

Me thinks alcohol caused that by sucking water out of the air into the fuel and pump

The crystals and powder would be from fuel but even running alcohol I didn’t have that or see that in the three that I have rebuilt. I buy WD40 by the gallon and have it in spray bottles so I spray the heck out of everything. It easily slide out by keeping it square coming out as the clearance is close. Vasoline is prefect for lubing the seal and pop’s in with your fingers. Pay attention and make sure it’s installed in the right direction. Like I said pictures help a lot when it’s reassembly time.

If you haven't finished the pump rebuild yet ...there are a couple vids on Youtube as well. Basically putting words to what John has chronicled here. In the one vid i remember, the guy doing the work and in the environment SHOCKINGLY had success with his, so it gave me courage. It worked for me!

I had to go out of town so am planning to finish it this weekend. I am having trouble getting the eccentric insert out.

I looked for videos but did not find any...... Got any links?

I couldn't find it but, if that's the 'ring' as seen in the last pic John shows then, i don't rember how i got it out...looking at it I'd probably 'criss-cross' a couple screwdrivers an leverage against some soft (maybe wood) bridges.

...if it's the 'coin' piece below that ...try using shop air to 'hydraulic' it out.

I sprayed the heck out of it with WD40 and used may two index fingers to squarely pull it out.

Thus far that has not worked......... All I managed to do is be stupid and chip an outside edge. I think it will still be ok to use, but I gotta get it out first.

Remember it’s pinned on the bottom so it can’t spin.

Thank you! Did not know that! very helpful............

Well I think I am back in business. Pumps fine and no leaks. John - thank you very much for your guidance. It was invaluable!

The eccentric insert was not coming out without help. I ended up having to make a puller for it. The bottom plate was not bad at all, but I cleaned it up. 0.0015" cleaned it up but I took an additional 0.0005" off for a total of 0.002". After I took the picture, I lapped it and its quite flat and smooth. The top wear plate had no visible wear to speak of.

I ordered a 8AN plug on Monday from Jegs. It never showed up. Unbelievable how poor the service has gotten. So I spent a few hours and hogged a plug out. Also went through the filter and replaced the element and o rings.

More pics.......

Well done!

Very nice job and thanks. Glad I could help.