Broken Fuel Pump Outlet Fix - Kawasaki Versys Forum
 
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post #1 of 17 (permalink) Old 07-31-2011, 07:54 PM Thread Starter
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Broken Fuel Pump Outlet Fix

Removed the tank on my 08 to clean the air filter and (tried to) carefully place it on a towel on the frame without removing the fuel line. It slipped, snapping the outlet like a twig and put a nice winger in the fuel tank.

Here's the damage:



Called my dealer and found out that you have to replace the entire fuel pump at $300; there is no replacement for the cheesy $0.10 plastic outlet by itself.

Reading Zonkelnut's post on the forum about a possible fix I ran down to the hardware store and bought this for $1.69:



Zonkelnut suggested sliding the metal tube inside the plastic outlet with some glue to create a more rigid outlet. The diameter of the brass tube fits perfectly inside the outlet with just enough tension to hold it in place.



I pushed the tube all the way into the housing then backed it out an eighth of an inch or so for fuel flow clearance. With the broken piece of the outlet snug in place against the housing side with the tube inserted I made a mark on the brass tube and cut it to length.

Using JB Weld I carefully applied the epoxy in such a way as to leave non exposed inside the outlet housing. Here's the final fix.



I'll let it set for a day before reinstalling. Then it's off to the dent removal guy!

Hope this helps anyone with the same problem. This is a design flaw that could have been prevented with a stronger (metal) outlet tube.

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post #2 of 17 (permalink) Old 07-31-2011, 08:11 PM
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Quote:
Originally Posted by Humunn View Post
Removed the tank on my 08 to clean the air filter and (tried to) carefully place it on a towel on the frame without removing the fuel line.
That's a risk to take... I like your fix a lot though. It looks really good. So how deep in is it, when set at about 1/8" from bottoming out? You could maybe add a touch of JB weld around the tube close to the pump where you already applied it. It seems to be a bit lacking down the side.

Last edited by invader; 07-31-2011 at 11:32 PM.
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post #3 of 17 (permalink) Old 08-01-2011, 01:05 AM
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Good fix and use a little more epoxy around the joint area.

Hope it works.

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post #4 of 17 (permalink) Old 08-01-2011, 01:08 AM Thread Starter
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That's a risk to take... I like your fix a lot though. It looks really good. So how deep in is it, when set at about 1/8" from bottoming out? You could maybe add a touch of JB weld around the tube close to the pump where you already applied it. It seems to be a bit lacking down the side.
It protrudes in about 1/4" or maybe a little more. Very sturdy. I used a touch of JB Weld on the brass "liner" but not near either end so to not have any weld spill over into the tube.

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post #5 of 17 (permalink) Old 08-01-2011, 09:27 AM
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Given the number of reports of folks breaking it (with their fingers), it appears that the nipple is at least somewhat inherently weak and as such, this might be worthwhile preemptive fix too, i.e., slipping the reinforcing tube in before it breaks.

Would anybody venture a guess as to the potential effect on flow rate through the smaller ID tube?

.

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post #6 of 17 (permalink) Old 08-01-2011, 10:34 AM
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I don't think Flow Rate will matter all that much as the way the pump works is it pumps to keep the pressure in the line constant so the injectors always have fuel. Once its upto pressure, keeping it at pressure is pretty easy and does not require a very high flow rate.

Very nice fix BTW. I may take the preemptive measure myself!

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post #7 of 17 (permalink) Old 08-02-2011, 12:34 AM Thread Starter
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...this might be worthwhile preemptive fix too, i.e., slipping the reinforcing tube in before it breaks.

.
Agreed. Easy to do and there is enough tension on the tube that it could be installed with little or no adhesive.

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post #8 of 17 (permalink) Old 06-25-2013, 03:25 PM
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Understand its an old thread, but if OP is still active, how is the fix holding up? I broke mine too dropping the tank(trying to balance the tank and troubleshoot a sparking problem). I bought the brass tube and its a snug fit ... Will do the remaining today.
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post #9 of 17 (permalink) Old 06-25-2013, 08:18 PM
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How would inserting the brass tube into an unbroken housing go, as a preventative measure if you do regular servicing.??
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post #10 of 17 (permalink) Old 06-25-2013, 08:59 PM Thread Starter
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How would inserting the brass tube into an unbroken housing go, as a preventative measure if you do regular servicing.??
I think that would be a very smart idea. There is enough tension between the outside of the brass tube and the inside of the plastic connector that you would not need adhesive; simply cut to size and insert. Done!

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post #11 of 17 (permalink) Old 06-25-2013, 09:02 PM Thread Starter
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Understand its an old thread, but if OP is still active, how is the fix holding up? I broke mine too dropping the tank(trying to balance the tank and troubleshoot a sparking problem). I bought the brass tube and its a snug fit ... Will do the remaining today.
I sold the bike last fall (September) and never had an issue between the time I repaired it (date of first post) and then. It was certainly worth the $$ to try it versus buying a complete fuel pump!

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post #12 of 17 (permalink) Old 06-25-2013, 09:05 PM
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Thank You. You saved me a good amount of $$.

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I sold the bike last fall (September) and never had an issue between the time I repaired it (date of first post) and then. It was certainly worth the $$ to try it versus buying a complete fuel pump!
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post #13 of 17 (permalink) Old 06-25-2013, 09:09 PM Thread Starter
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Thank You. You saved me a good amount of $$.
You are welcome. I about croaked when I found out you couldn't simply replace just the plastic connector (a very poor design IMO) but rather were stuck to fork out $300 plus for the entire assembly! Someone should take the idea and sell "preventative maintenance" kits for $10 each with a few instructions!

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post #14 of 17 (permalink) Old 06-25-2013, 09:58 PM
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The solution is very clever! I would shop eBay for a replacement and keep using that one in the meantime.

Good job!


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post #15 of 17 (permalink) Old 06-25-2013, 11:24 PM
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Definitely doing this premptively next time the tank is off. Adding more JB Weld down where it is prone to break would be a good idea if anyone is squeamish about the tube insertion. Maybe a bit if fiberglass mat in the mix too.

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post #16 of 17 (permalink) Old 06-27-2013, 12:41 AM
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The solution is very clever! I would shop eBay for a replacement and keep using that one in the meantime.

Good job!


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If the repair is done right it's more than likely stronger than the stock tube.
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post #17 of 17 (permalink) Old 06-27-2013, 08:17 AM
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Keep us updated on the long term results. I would be somewhat concerned with a potential fuel leak in a location not readily visible that could have space shuttle catastrophic effect.

Thanks for the post. If nothing else, it educates us folks who haven't removed the tank (yet) and will be very, very careful when the time comes.
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