Save $220 by not doing as I did - Kawasaki Versys Forum
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post #1 of 21 (permalink) Old 08-12-2012, 12:22 PM Thread Starter
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Save $220 by not doing as I did

I was working on my Versys. The gas tank bolts were undone but the fuel pump etc. was still connected. I had rotated the tank aside and had it rest on a support next to the bike, as I had often done.

Then I maneuvered the tank a bit carelessly and broke the plastic nipple off of the fuel pump.
That is not a plastic nipple replacement at $6, that is a fuel pump replacement at $220.

Don't be lazy as I was, disconnect your gas tank completely and set it aside.

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post #2 of 21 (permalink) Old 08-12-2012, 12:53 PM
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Ouch!


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post #3 of 21 (permalink) Old 08-12-2012, 01:18 PM
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Looks like it broke too close to the pump housing to allow repairing it.

http://www.kawasakiversys.com/forums...ead.php?t=9467

http://www.kawasakiversys.com/forums...ad.php?t=16462

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post #4 of 21 (permalink) Old 08-12-2012, 02:46 PM
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http://www.kawasakiversys.com/forums...ad.php?t=16462

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post #5 of 21 (permalink) Old 08-12-2012, 08:22 PM
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I would certainly attempt the brass tube and JB Weld repair first before laying out $220 for a new fuel pump assy.

I have used JB Weld several times in the past for fuel system repairs with successful results.


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post #6 of 21 (permalink) Old 08-13-2012, 04:42 PM Thread Starter
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Alright, brass tube and JB Weld repair it is.

Just know that if my crotch turns into a gasoline-fed fireball, I will hunt you down, find you, and sternly wag my index finger at you.
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post #7 of 21 (permalink) Old 08-13-2012, 10:29 PM
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Let us know how it goes... the repair and/or the fireball.

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post #8 of 21 (permalink) Old 08-14-2012, 08:30 AM
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Alright, brass tube and JB Weld repair it is.

Just know that if my crotch turns into a gasoline-fed fireball, I will hunt you down, find you, and sternly wag my index finger at you.
Good lord aren't your genitals worth 220? Holey balls of fire!





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Last edited by MTS; 08-15-2012 at 09:53 AM.
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post #9 of 21 (permalink) Old 08-14-2012, 08:20 PM
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Alright, brass tube and JB Weld repair it is.

Just know that if my crotch turns into a gasoline-fed fireball, I will hunt you down, find you, and sternly wag my index finger at you.
You can fix that with JB, too!


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post #10 of 21 (permalink) Old 08-14-2012, 09:26 PM
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If it goes to the fire balls. For the love of God, Make sure you get a picture to post.
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post #11 of 21 (permalink) Old 08-15-2012, 02:57 AM
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I would try this.

http://www.plastex.net/
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post #12 of 21 (permalink) Old 08-15-2012, 09:22 AM
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I would try this.

http://www.plastex.net/
Quote from their order page...
"THIS PLASTEX KIT INCLUDES 5 GRAMS OF WHITE POWDER, 1 LIQUID, 1 APPLICATOR BOTTLE, 1 NEEDLE, 1 MOLDING BAR, 1 VIDEO CD. SMALL PLASTEX WHITE KIT.
THIS KIT IS ENOUGH TO MAKE ONE SMALL TAB OR 3" CRACK REPAIR
. "

All this for $13.95 (plus shipping?) I think not.

Nothing beats JB Weld... and you can pick it up at Walmart or just about anywhere else right down the street... enough to make probably a 24" crack repair.

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post #13 of 21 (permalink) Old 08-15-2012, 09:56 AM
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Good lord aren't your genitals worth 220? Holey balls of fire!
The last fuel leak I fixed lasted two years but was on a lawn mower and was out side in the winter. Hope yours last longer!





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post #14 of 21 (permalink) Old 08-19-2012, 04:50 PM
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Just BECAUSE I've seen so many posts on here from guys that do almost anything RATHER than properly removing the tank, I took a few pics last time I removed the tank. To slide that red plastic "U-thingie" outboard to slip off the fuel line, you use a small (1/4"...?) slot screwdriver; slide it into the slot and GENTLY rotate it sideways which pulls the "U-thingie" out of its slot allowing the fuel line to be removed. (Some fuel WILL drip out, so wrap the end of the fuel-line with a cloth.) Here're the pics:
Attached Images
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post #15 of 21 (permalink) Old 08-19-2012, 07:26 PM
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Hope you got it fixed. ANs didn't set yourself on fire!

Gives a new meaning to "Great Balls Of Fire!"

BUT thanks for the heads up...I'll follow the manual as I'm a cheap KLR rider in the Versys game. I know they say "You learn from your mistakes" But I don't want to pay $220.00 per class!

Or was that look THEN leap?
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post #16 of 21 (permalink) Old 08-19-2012, 08:16 PM
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Here're the pics:
That's a spooky looking' 2x4 Eddie...

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post #17 of 21 (permalink) Old 08-19-2012, 09:32 PM
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That's a spooky looking' 2x4 Eddie...
Eddie is a master cabinet maker, and deals with beautiful wood specimens.
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post #18 of 21 (permalink) Old 08-20-2012, 10:33 AM Thread Starter
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Originally Posted by fasteddiecopeman View Post
Just BECAUSE I've seen so many posts on here from guys that do almost anything RATHER than properly removing the tank, I took a few pics last time I removed the tank. To slide that red plastic "U-thingie" outboard to slip off the fuel line, you use a small (1/4"...?) slot screwdriver; slide it into the slot and GENTLY rotate it sideways which pulls the "U-thingie" out of its slot allowing the fuel line to be removed. (Some fuel WILL drip out, so wrap the end of the fuel-line with a cloth.) Here're the pics:
Thanks Eddie!
Now that I know how easy it really is to remove the fuel tank fully (preventing fireballs gets you intimate with the related motorcycle parts and connections) I will definitely do so.

The "setting the tank aside on a barstool/stack of boxes/whatever" method is certainly not worth the risk.


EDIT:
The JB Weld repair has held so far, no photos yet of Great Balls Of Fire.
I too hope that it lasts longer than 2 years, and I will be inspecting it several times before that much time has elapsed.
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post #19 of 21 (permalink) Old 08-20-2012, 12:54 PM
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That's a spooky looking' 2x4 Eddie...
It's VERY DIFFICULT to find 2x4s that have THAT particular strain of "lumberitis", a form of cancer-of-the-wood....


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Eddie is a master cabinet maker, and deals with beautiful wood specimens.
Invader (as usual) has my 'number'...!


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post #20 of 21 (permalink) Old 08-20-2012, 12:59 PM
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Thanks Eddie!
Now that I know how easy it really is to remove the fuel tank fully (preventing fireballs gets you intimate with the related motorcycle parts and connections) I will definitely do so.

The "setting the tank aside on a barstool/stack of boxes/whatever" method is certainly not worth the risk....
You are VERY welcome! When I joined this "fraternity" back in 2008, a bunch of REALLY GOOD guys helped me out when I posted questions, me being an FNG.



Now as I do things that initially concerned me, I try to help out the other FNGs... ...!


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