Join Date: Jun 2016
Location: The wilds of North idaho
Year/Make/Model: 2004 VN 1500E7
Color: green over white
Fuel pumps on these bikes generally give very little trouble. I have a friend who had to replace the one on his Nomad at 78,000 miles. I don't recall anyone else I know needing to replace theirs. I'm wondering if you have an electrical issue that's overloading the pumps.
I had an issue a few years ago, my bike would just shut itself off when I was going 70MPH down the freeway or sitting in traffic, always at random times, sometimes two or three times in a day and other times not at all for months. I had to keep replacing 10A ignition fuses. I limped it into a shop and they told me my driving lights were shorting out. They rewired them and charged me 80 bucks. THREE WEEKS LATER IT DIED AGAIN. So I took it to a dealer this time. The mechanic said he would bet it was the kill switch because every time I'd turn the key on then flick the kill switch to on, the fuse would pop. So I ordered a new kill switch, and you have to buy the entire assembly, so it was like 178 dollars. I installed the new switch and wires, turned the key on, flipped the kill switch and....POP! went the fuse. So I tore the bike down, tank off, and started running down wires from the battery. When I came to the fuel pump, I discovered it had come off the metal tang holding it onto the frame and was moving around under the tank. Upon closer inspection, I noticed a little worn spot in the hot wire where the pump had been rubbing against the tang. And every so often, at random times, that bare spot on the wire would touch the frame and blow the fuse. I put a dab of silicone on the wire, let it dry and taped all the wires up, and taped them to the frame as well, and I have not had an issue since.
all that is to say I wouldn't keep throwing parts at it until I was certain of the cause.