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Buell Forum » Big, Bad & Dirty (Buell XB12X Ulysses Adventure Board) » I think that my fuel pump died « Previous Next »

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Mark_weiss
Posted on Saturday, July 08, 2017 - 07:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Uly would not start this morning. Twisted the key, thumbed the engine cut-off, and then there was this noise. It sounded a lot like a fuel pump, but not one that was submerged in fuel inside the frame. More like one that was running dry, sitting on a bench.

I primed the system a few times and then the bike would start, but only run roughly for a few seconds before going silent.

The low fuel light is not on and really was not due for about 80 more miles. Nonetheless, I poured two gallons of fuel into the frame and tried again. Same sound, same result.

As I type, the frame is draining (siphon).
I'm only at 72k miles right now. That seems a little early for pump failure. Is there a weak spot in the system that allows an internal leak? Some BMWs have a failure prone internal hose, but you can remove the fuel cap and hear the internal gas geyser, so those are easy to diagnose.
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Rays
Posted on Saturday, July 08, 2017 - 08:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Mark, the ribbed fuel line that loops back from the pump to the regulator can wear through or split so one place to check carefully when you have it apart.
This post from late last year refers to the issue. Not a common issue but certainly something to eliminate.
http://www.badweatherbikers.com/buell/messages/384 2/798544.html?1485056389
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Mark_weiss
Posted on Saturday, July 08, 2017 - 09:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That's the same hose that fails in BMWs.
My Uly exhibited no early warning signs at all. Yesterday the bike ran fine. Today it was difficult to start (first time for that) and would only run for a few seconds.

(Message edited by Mark_weiss on July 08, 2017)
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Mark_weiss
Posted on Sunday, July 09, 2017 - 08:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It turns out that the u-hose is not leaking. And the fuel pump runs with no odd sounds. There are, however, a few internal leaks.

I removed the pump assembly and briefly ran the pump, just to listen for odd sounds. Nothing. Next, I took my life in my hands and put enough fuel into a large bowl so that I could submerge the pickup end of the pump. I had no way to seal the outlet so that the system would run under pressure, but I thought that if there was a hose leak, a trickle of fuel would be better than a 40 psi geyser. With the pump connected to wiring and the inlet and outlet submerged in fuel, I switched on power. The pump ran, the fuel in the bowl turned black (?), and I noted two leaks. With no back-pressure, just the pump running free, fuel leaks from where the regulator is pressed into its housing and from where the fuel filter is fitted into the regulator housing. Under pressure, the leaks are probably impressive.

So far, I have not been able to find a listing for whatever seal or o-ring is used to seal the regulator, nor the filter.
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Mark_weiss
Posted on Sunday, July 09, 2017 - 09:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well poop. I decided to disassemble the pump/regulaor/filter and look for part numbers. All three parts should have an interchange out there somewhere, but I learned that is not what I need. There are four prongs that pop into the regulator retainer and hold it to the housing. My Uly only had three. A little closer look and I could see where the regulator's O-ring had been forced out of the housing.

So there's the problem. The housing does not seem to be a universal part and may only be available with a complete pump assembly.

Not what I wanted to find.
Photos to follow once I figure out how to get Google Photos images to show up over here.
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Jasonmcelroy
Posted on Sunday, July 09, 2017 - 10:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You can get a regulator with the two necessary o-rings here for $29: http://www.highflowfuel.com/i-13398610-new-intank- efi-fuel-pump-w-pressure-regulator-buell-ulysses-x b12-xb12x-xb12xt-2006-2010.html

Whole pump assembly including regulator too for $80: http://www.highflowfuel.com/i-13398610-new-intank- efi-fuel-pump-w-pressure-regulator-buell-ulysses-x b12-xb12x-xb12xt-2006-2010.html

I've been using their pump and reg for the last few thousand miles with no troubles. Drop in replacement.

I don't work there, just a satisfied customer.

Jason
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Mark_weiss
Posted on Monday, July 10, 2017 - 01:07 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

the missing locking tab:

The missing tab


the bulging o-ring

bulging o-ring
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Brother_in_buells
Posted on Monday, July 10, 2017 - 03:16 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Maybe possible to secure it with a small zip tie!?
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Rays
Posted on Monday, July 10, 2017 - 04:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Mark, I don't know if there are any still in the parts systems but that plastic body was identified as a spare in the 2006 Parts manual - P0080.3A8 Housing, Regulator, w/hoses.
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Hughlysses
Posted on Monday, July 10, 2017 - 09:01 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

the bulging o-ring

Courtesy of the ethanol industry no doubt.
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Mark_weiss
Posted on Monday, July 10, 2017 - 10:38 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

No ethanol problem. The issue is that the tab for the retaining ring broke off, retention pressure on the regulator was lost, and then fuel pressure pushed the o-ring out of place.
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Natexlh1000
Posted on Monday, July 10, 2017 - 11:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If I faced that, I would be really tempted to try making some sort of tapped metal bridge to apply mounting pressure with proper screws.
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Mark_weiss
Posted on Wednesday, July 12, 2017 - 11:01 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have some stainless steel zip ties that I am thinking of trying. The base of the retaining arm has a slot that a tie will fit through quite nicely. Then the tie can loop through the retaining ring as well. I would tie all four spots.

The o-rings are completely undamaged and with a light greasing the regulator slipped easily back into place.
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Mark_weiss
Posted on Monday, July 17, 2017 - 11:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Metal 'zip ties' did not work. Stil too much flex. Even on the bench, when I covered the fuel outlet to fully pressurize the pump assembly, the regulator stopped sealing to the housing.

I've ordered parts. Some are avalable through H-D, some others are coming from a supplier "Vintage Parts". VPs prices are quite reasonable but their shipping is very high. $15 min.
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