Bike had been sitting for just over 6 Months as ive been ill. Its been started probably 5 times during that time and left to run until the fans cut in. I was feeling better today so i drained the fuel put in fresh and went for a ride. Luckily only a mile or so down the road the engine shut off. It started back up ran for 50ft and shut off again like no gas. Each time it would fire run,rev a few times and shut off. Pushed it home checked for voltage at the pump and it was there even as the engine was shutting down. Drained the tank took of the tank and then the pump unit and found this !!!!! Now what ? The bottom of the tank is rusty, Looked fine from the gas cap This can be fixed with tank treatment but what about the pump,fuel strainer,fuel filter. Are these parts are available and from where?? Are there after market parts that can be used?? Another issue i found and probably the reason for the cutting out is there is a short in the ground wire on the pump harness. Its where the wire goes into the sealant between inside and out side of the tank. How to fix this, i believe there used to be a fix for this but its not available anymore.
Bike had been sitting for just over 6 Months as ive been ill. Its been started probably 5 times during that time and left to run until the fans cut in. I was feeling better today so i drained the fuel put in fresh and went for a ride. Luckily only a mile or so down the road the engine shut off. It started back up ran for 50ft and shut off again like no gas. Each time it would fire run,rev a few times and shut off. Pushed it home checked for voltage at the pump and it was there even as the engine was shutting down. Drained the tank took of the tank and then the pump unit and found this !!!!! Now what ? The bottom of the tank is rusty, Looked fine from the gas cap This can be fixed with tank treatment but what about the pump,fuel strainer,fuel filter. Are these parts available and from where?? Are there after market parts that can be used?? Another issue i found and probably the reason for the cutting out is there is a short in the ground wire on the pump harness. Its where the wire goes into the sealant between inside and out side of the tank. How to fix this, i believe there used to be a fix for this but its not available anymore. View attachment 234838
Crikey that looks a mess. Looks like sand/cement to me? Whatever it is, it needs cleaning out, and the fuel system. All parts should still be available. I had the pump wire issue on mine last year and bought a replacement wire kit from SteinDinse. https://www.stein-dinse.biz/product_info.php?language=en&products_id=452298
1st option for me would be to have a good clean out and fit a new strainer, then give it a try. It looks like the strainer has become blind and collapsed, you may get away with cleaning and a bit of reshaping. If this does not work start looking at the more expensive/ intrusive options.
Is the fuel strainer available as no part number is listed for it. I think mine looks like it does because it was blocked, How is it supposed to look?
It is...almost. I used it on my 749 which I am confident is the same as a 999. One needs to connect an addition earth wire that exists on the 749/999 arrangement that goes onto the pump connector. If you compare the two items on a bench it will be obvious where the extra wire need to go. Otherwise, it was a perfect fit.
I have done some cleaning on the tank and its looking ok. I didnt want to use any acids because i was worried about the paint so i tried electrolysis. Not done it before but i had read about using it for tank cleaning a few years back. All you need is water,baking soda,metal rod and a power supply. I tried using a battery charger at first but the ones i have are smart chargers and would not work. Then i tried a old laptop charger which worked but the output was low and would have taken a week to finish so i ended up using a old desktop powersupply. I used i piece of wood to block the pump housing hole as you cannot use it as its aluminum. Filled it with the baking soda and water mix,dropped in the rod while making sure to insulate the end and where it came through the neck of the tank. Connected the power, positive to the rod and turned it on. 10 hours later the tank looks so much better and just needs a sealant applied.
Hello. I have used the products described below with success every time, they don't require any special handling/disposal methods, and they are supposed not to harm paintwork. Although, I wrapped my tank in a couple of layers of cling film just to be sure. The instructions are straightforward and it has removed the rust every time, but does not protect the new surface, so a light coat of oil should protect it until you use it again. I hope it helps, Tom. ------------------------------------------------------------------------------------------------------------------------------- If you're in the USA: This product is made and marketed there, and might help if your electrical solution isn't completely effective. Good luck. Tom. DAVID LEWIS Vice President, Sales HARRIS INTERNATIONAL LABORATORIES, INC. 2078 FORD AVENUE │ SPRINGDALE, AR 72764 PHONE: 479.756.9877 │CELL: 479.599.9540│FAX: 479.927.3202 www.EVAPO-RUST.COM www.WHITEWIZARD.us In UK: Frost Auto Restoration - Phone number and link to their site. Phone: 01706-658-619 - https://www.frost.co.uk/catalogsearch/result/?q=Evapo-Rust
Some additional information that might help if you wish to develop your method for electrolytic rust removal. I hope it is useful. Tom. https://www.qsl.net/2e0waw/rust.htm
The electrolysis “solution(see what I did there?) is genius....but I can’t help feeling an opportunity has gone begging: “Honey, have a look at this....OBVIOUSLY a carbon tank is required”
i dug out the sealant around the wires for the fuel pump and found this-- The one wire wasnt even soldered to the connector !
A known problem. There is a ‘Not Cheap’ repair kit (when in stock) https://ca-cycleworks.com/fwires.html
I did see that it was out of stock. RickyX did post a link to another alternative. Im wondering if i cant just solder the wires back on.
I managed to solder the wires back on the connector. Filled it with some JB weld and then sealed it with some tank sealer.I wasnt sure how well the JB weld would do with petrol. Tank is now sealed and im just waiting for it to dry.
Back together with fixed wiring,new fuel filter and sealed tank. Need to give it a wash and a test ride but starts and revs with no issues
I had to re-solder my fuel pump wires last summer, or may solder them for the first time by the look of it. Refitting the mesh strainer was a PITA. There just doesn't seem to be any room for it under the pump.
