1150 – bike cut out – wouldn’t start – recovery home – Fuse 6 – Help!

[DrAlf]

Would be an idea to check the link pipe whilst you've got this to bits if the bikes fairly old and possibly the fuel filter. See my thread here for the trouble the link pipe caused me.

Thanks for the that Hops. Had a good read through your thread - what a PITA. I'll make sure to check the link pipe when I've got the fuel pump assembly out. I'll also have some spare proper spec fuel hose on stand by. Ta

 

[DrFarkoff]

Fecking Twat cutting the fuel pump support off!!

All he had to do was rest the new pump against it and secure the pump and it would have been where the old one was!!!

Tips I would give Are:-

Get an Old rear tyre and put it on a work bench with a towel on the bench this gives you a stable base to work on You sort of tuck the end of the lower front tank lobe inside the rim part and balance it

You don't need to drain the tank completely a gallon in the lobe helps to steady it and gives you the opportunity to check out what the residue in it was? (i.e if you get a clear jug and mop out the last litre with a dry microfibre cloth you will get the dirt out and if you wring it into a clear vessel each time you will see how much water was in there?)

But before that To wire brush the exposed threads even with a dremel and get them as shiny as possible without damaging wires or pipes

Drip 3 in 1 oil on them a few times an evening before you put a spanner near them

Put a mark on the flange and the tank with a tippex marker to help you remember how the flange fits back in

When you just raise the flange from the side where the two small pipes are you will see the clips a terminal screwdriver with a bend makes it easier to slide the latching part off

While these bits are off check those two pipes are clear both through the flange and down from the filler neck if its blocked at the filler neck (filler drain ) do not stick a compressed air line on it as you force the dirt further in use a skinny bit of stainless wire and more 3 in 1 and get it cleared out

on reassembly just just use a pair of diagonal cutters to lift the latch over the catch on those wee clips

Indeed it does. New pump ordered - should be here on Friday hopefully. Not looking forward to changing it over!!

This was helpful though:

 

[DrAlf]

Fecking Twat cutting the fuel pump support off!!

All he had to do was rest the new pump against it and secure the pump and it would have been where the old one was!!!

Tips I would give Are:-

Get an Old rear tyre and put it on a work bench with a towel on the bench this gives you a stable base to work on You sort of tuck the end of the lower front tank lobe inside the rim part and balance it

You don't need to drain the tank completely a gallon in the lobe helps to steady it and gives you the opportunity to check out what the residue in it was? (i.e if you get a clear jug and mop out the last litre with a dry microfibre cloth you will get the dirt out and if you wring it into a clear vessel each time you will see how much water was in there?)

But before that To wire brush the exposed threads even with a dremel and get them as shiny as possible without damaging wires or pipes

Drip 3 in 1 oil on them a few times an evening before you put a spanner near them

Put a mark on the flange and the tank with a tippex marker to help you remember how the flange fits back in

When you just raise the flange from the side where the two small pipes are you will see the clips a terminal screwdriver with a bend makes it easier to slide the latching part off

While these bits are off check those two pipes are clear both through the flange and down from the filler neck if its blocked at the filler neck (filler drain ) do not stick a compressed air line on it as you force the dirt further in use a skinny bit of stainless wire and more 3 in 1 and get it cleared out

on reassembly just just use a pair of diagonal cutters to lift the latch over the catch on those wee clips

All very helpful - thank you for posting.

I don't have a spare tyre (moved house recently and binned them) or a microfibre cloth but I get the idea. Appreciate that I don't have to drain the entire tank and have rigged up a cardboard support for the tank already. I've also started soaking the pump assembly retaining bolts in WD40 and I'll give them another good soaking tonight. Fuel pump and hose should be here tomorrow ready for a weekend of fun

 

[DrFarkoff]

Dag Nab it! Not you too! Sorry but WD40 down;t get in my garage unless its a Dire emergency, Its really really really not good around some rubber materials

Seriously go find a wee squeazy bottle of 3 in 1 oil at a small hardware shop Its will last far longer than the WD and won;t dry out the same

I've also started soaking the pump assembly retaining bolts in WD40

 

[warmshed]

http://www.youtube.com/watch?v=1bl3H89xtS8

 

[Packer]

To help free seized threads use a proper penetrating fluid such as Plus Gas. Far better than WD40 et al. Those wee flange studs are weaker than a weak thing, be warned.

 

[DrAlf]

To help free seized threads use a proper penetrating fluid such as Plus Gas. Far better than WD40 et al. Those wee flange studs are weaker than a weak thing, be warned.

Okay - thanks for the heads up. I've done this job at least once before and remember being extremely nervous of the studs the last time round. I've read before that you can get away with snapping a single stud but more than one is a tank right off - is that right

 

[Timolgra]

Okay - thanks for the heads up. I've done this job at least once before and remember being extremely nervous of the studs the last time round. I've read before that you can get away with snapping a single stud but more than one is a tank right off - is that right

It wouldn't mean the tanks a right off, loads of ways to fix it including the simple one of drill and tap to 5mm (I think) and screw a bolt in from the inside so it becomes a fixed stud, use Loctite to hold it and copperslip to stop it happening again.

 

[DrAlf]

I have to confess to bottling out here - I was too worried about snapping the tank studs so took the tank along with all replacement parts over to the ever helpful Steve at MotoScot earlier today. Tank apart already - filter sock had come off and consequently pump had seized due to sucking in god only knows what.

New sock on order - tank to be returned next week. Reckon it's almost sorted but I will update next week. Thanks for all the help

 

[Timolgra]

That's hopefully a good result DrAlf with a definite cause and solution, it's also possible some paint flaked off the inside of the tank and got into the pump so may be worth them having a look in there whilst it's apart, either way with the sock being off is only a matter of time before it would fail

 

[Packer]

Pedant mode on

Write off, not right off. Right off means completely removed, write off means beyond economic repair.

Pedant mode off.

Sorry about that but it's Friday, a supplier bought me an excellent lunch with some very fine ale to wash it down. Drygate, Glasgow.

Good result for the OP and normal service should be resumed once the tank is right on

 

[DrAlf]

Writeo - fuel tank collected from Steve at MotoScot. Rapid turnaround since I dropped the tank off on Friday afternoon and parts were required (sock filter). Pump changed, filter changed and new sock filter. Moment of truth tonight - hopefully back on the road

 

[DrAlf]

Fixed Replacement fuel pump has sorted the issue. Bike now starts and does not blow fuse 6. Fuel pump seems slightly louder on start up but other than that fine. As a bonus I've had the fuel filter replaced and have also taken the time to tidy up some of the wiring.

For reference, my issue was the following:

1. Bike stopped mid ride.
2. Fuse 6 shown to be blown
3. Replaced Fuse 6 - fuse blew on ignition
4. Replace Fuse 6 - disconnect fuel tank electrical connector - fuse does not blow - therefore issue is tank side and either wiring or pump related.

**Note: If fuse 6 blows without the tank connected your issue is wiring loom related - check for exposed wiring around injectors (Mike O) and the US canister wiring loom running along the subframe (Grizzly)


Thanks for all the help and hope this helps someone else

 

[Grizzly]

Glad Your Sorted

That's good news. Another symtom/cause to try and remember Cheers....................Grizzly