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Old 05-02-2011, 09:12 AM   #1
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Outlaw exterior fuel station - pump fix !

The credit for this fix goes to Don Shaffer (DGShaffer). This fix is an awesome example of the benefit of these forums.

Problem: Damon/Thor Outlaw has exterior "fuel station". A pump to pull fuel out of main tank and use it to fill motorcyles, etc. A couple weeks ago (my coach is now about 1 yr old) when attempting to fuel my dirt bike, the pump stopped. ???

Fix: Not being super mechanical, I was planning to bring into the dealer and likely get a new pump.

Her is the kicker. I'm 99% sure that if I had the dealer "fix" this problem it would have resurfaced again in 6-12 months. Whereas, I think it's likely that the following fix is a long term solution.


Don heard about my problem and suggested the following - which worked PERFECTLY! So, the following is all Don's advice from another thread.

1. The impellers in the pump get swollen and eventually bind on the case of the pump. Too much bind, fuse blows, no action. If all you do is replace fuse, same thing will happen.

2. Remove top cover from pump case (small amount of fuel will spill out, so place a large freezer type plastic bag under pump to catch spillage and minimize mess in the storage bay.)

3. Impeller "gears/blades" can be pulled out easily by removing the small plastic chock in the middle of one of the gears.

4. Use file and/or sand paper to file off a small portion of the top of each gear ear (I used a file to take, maybe 1/32 or more, of each ear and used sand paper to touch things up).

5. Carefully wipe off sanding residue to keep it out of pump. Replace gears. Replace top of pump.

6. Replace 15A fuse (it was in slot 12 in my fuse box).

7. Test pump.

This worked like a charm for me!!

Thanks again Don.


Mike Ahern
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Old 05-02-2011, 09:20 AM   #2
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Nice write up Mike.
Ethanol... :(
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Old 02-19-2012, 09:38 AM   #3
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Thank you both for this information. I bought a used 2008 Outlaw 3808 in December 2011 and could not get the fuel station to work. After searching the web I found this post. As a result, I was able to fix it myself. Awesome write up!

-Ken
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Old 02-19-2012, 10:52 AM   #4
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I'm glad it could help you solve your problem.
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