Hi all, My 996 as strung a fuel leak and after taking a look it appears to be due to the Fuel Level Sensor nut being split. My problem is that I can't find anywhere that sells them. Ideally I would like to replace it with the aluminium nut rather than the standard plastic one, but at the moment I'd be happy with either. Does anyone know where I can get one? Thanks
There is someone in the US that supplies them. Ca Cycleworks Replacement Nut for Fuel Sender | ca-cycleworks.com or here CORSE DYNAMICS Billet Fuel Sending Unit Replacement Nut - Ducati 1990-2003
Thanks for those, the Corse Dynamics was the only I could find, but I was kind of hoping there would be a UK based company that would do them, for delivery reasons as much as anything. Does anyone know if we have anywhere?
I have a lathe so I could make one. Does anyone know the thread size inside the nut and any other dimensions out of interest. Corse Dynamics quote two sizes for sale 1.1892 and 1.2052 inches.
Thanks for the replies. @Red998 - that would be great if you could. Not sure on dimensions though, not really got anything to measure accurately either, only a tape measure which I'm guessing won't be quite accurate enough. Corse Dynamics say the 1.2052 is for 5% of 2001-2003 bikes, mine is unfortunately a 2001 so could fall into either as they do not give specifics regarding the different bikes. I'll take it off and see if I can get accurate measurements though. @locknload595 - I'll have to see what state it is in when it is removed, it is actually nearly split into two so might be a bit far gone. Thanks
The connector block will have to be removed to fit a new nut, this will help. Steve Connector pin removal.pdf
I think Ducati only sell the complete sender assembly? There was a thread a while back where someone said he was planning to make some, I'd like one myself and said so on the thread! Several years ago I bought an aluminium nut from the USA as a 'spare' in case the one on my 916 split (it hasn't yet) but when I was fitting the fuel sender into the Monster tank I used it instead of the plastic one that seemed a bit cross-threaded. The two US supplied nuts linked to look good but the problem I find with most US suppliers is that they go silly with the postage costs once it's outside of the US, and often charge more for the post than the item (when it really doesn't cost that much). If anyone can make them at a reasonable price I'd definitely get one as I'm sure others would (same nut fits several models; 916 - 998, Monster, SS etc. so I think it'd be worth someone's while to set up for making them. As for the OP, if you're desperate you can have the old plastic nut I removed from the Monster, the first couple of threads are a bit chewed but the rest are OK and it's not broken so should work, at least until a decent alloy one can be sourced. Alternatively if anyone is prepared to make them and wants a sample to copy, I'll happily send it to you...
I have a few dimensions thanks to Birdie. The nuts are pretty big and I would need to buy some tooling, If I had enough interest I would make and sell a few but otherwise the cost of the tools and materials wouldn't make it worthwhile for me to produce a few as tooling is pretty expensive and I would need to cover the cost of it, I am happy to break even but because of the cost of the tooling I do need to sell them as some of the drills and taps are silly money. I would like one to measure if anyone can at least let me have one to measure which I would return, I don't want to deprive anyone though.
As above I've got an unbroken one you can have, unless the OP wants to 'swap' it (use mine and send you his)? It's from an SS/Monster fuel sender but is the same as the 916 - I know this because the alloy one I bought for the 916 fits the Monster fine, I think it's a 28mm thread and measures 36mm across the flats. I don't know how much interest there is for you to produce them but I'd take one so there's two from this thread...
I have just emailed the two places in the US to see what delivery will be. I have also enquired into delivery/discount on a bulk buy of 20 to see if that is worth doing. If there is not much difference on delivery then it will mean anyone on this forum that needs one can get one without paying the delivery premium. I'll wait to see what they come back with and go from there. If they are after crazy money though, I might take you up on the offer @Dukedesmo just to be able get it back on the road. Will be happy to send mine to @Red998 for sizing reason if required as well.
^^ Very true, the tooling would be expensive for me as I would also need a couple of big drills and a reamer on top of that judging by dimensions of the nut and from the little information I have. I would like to look at a nut to see what they are like. I have the time to make them but don't want to spend a fortune on tooling and not be able to cover the costs back. If a bulk buy could be arranged I'd be in for one nut at least.
Ok, I have a 28.5 drill also a flat bottomed one, 30x1.5 taps and a 24.5 drill for the centre bore.. Just need to order the stock, I intend using 1 3/8" hex ally bar, to save machining time.
That's all the tooling I intended to buy or drill it to slightly less then to 28.5mm and finish with a reamer. I think, and as you have made them before, that is all that's needed. Sadly the tooling is very expensive and unless you are making big batches it's a lot of money to fork out on tooling for just one item to be made. If I bought the above i would need to at least break even on tooling costs. I spend quite a lot on materials just doing a few bits every now and again, as it is not my professional business, and I do not have access to cheap tooling or materials.
Wanted to get some, 1 7/16" in 2014 grade but it was difficult to get. So the slightly smaller 1 3/8" it will be. I am real busy with Valencia prep but that's another story. Looking to get this underway on my return w/c 12th may.
Great, let us know when you're ready. Maybe start a new thread, I would think there'll be good interest as this is a problem that will only get worse as these nuts get older and more brittle, anyone with a bike that has this nut should consider getting a spare IMO, because you just know that if you don't, it will break when there's no longer a supply... As Mr. R says the spanner size is unimportant, the only spanner I've got big enough will be an adjustable, a socket won't work and it's not as if they need torqueing up. I'm definitely up for one.
