I started cleaning the tank yesterday with vinegar and a scotch-brite scouring pad. I had let the vinegar sit in it for a while. It seemed to work pretty well, it was just hard to reach all of the areas of the tank inside with my arm. I finished that today, and would say I got 95% of the rust out, much better than before, only time will tell if I got enough. I think the pump failed electronically anyways, not due to rust clogging it up. I rinsed the tank out with lots of alcohol (not the drinking kind), and let it dry. After all that, I had to install the new fuel pump in it's housing, being sure not to break any of the plastic clips. The new filter was a little larger than OEM, so it was a hard fit, and I had to cut a tiny piece of plastic out that fit around it since the part that kept the filter on was slightly different, but I made due, and it seemed like it worked without hurting anything. I got the new o-ring installed, which was definitely needed by seeing how compressed the old one was. The hardest part was installing the fuel level sender bracket to the pump assembly, since I had to have both parts in the tank and then get it clipped in, but it finally happened after several attempts. I attached all fuel hoses, vent lines, electrical connections, and saw if she was thirsty...... and she WAS!!!
It started right up, without hesitation and sounded good in all RPM ranges.
I checked for leaks and took her to the gas station to fill up. She still rides like new. The fuel level sender seems to be working and I fixed a bad connection on the battery meter while I was in there. All in all, I'm happy I got it all fixed up for a $70 pump and can put my new gear to good use and have a good season of riding this summer. I appreciate all the help and offers here.-Wheaton Jr.
Video of starting up (after being warmed up)
https://www.youtube.com/shorts/Cf57zzNzRNQ
old vs. new o-ring
new helmet, pants, and boots
