Ok, sorry it's been so long, I hadn't forgot, I just never sat down and explained how the repair came out. I was able to get a brass elbow with a 3/8" NPT thread and a 1/4" barbed slip on fitting. The 3/8" was bigger than I wanted but all I could find. I had to go to a hose/hydraulics store to get that. I also got a piece of replacement fuel line to replace the stock line that had molded ends. I slowly drilled the hole in the top of the fuel pump bigger and bigger until I got it to just under the size of the 3/8" threaded elbow I bought. It turns out when you drill that hole out to that size, the "compartment" that it goes into in the other side of that plastic top is really narrow. When I drilled it out, the drill was slightly cutting into the walls on each side. I think this helped give the threads something more to bite into. I didn't tap the hole, I just let the threads cut their own path. With the walls on the other side, I wasn't worried about cracking it. After I threaded it in once to get threads, I pulled it out and covered the threads in JB Weld and then threaded it back in. I had scuffed up the top around the hole so more JB weld around the fitting would have a place to "grab" onto. After letting it dry, I put it back together and it hasn't leaked a drop. Cost me about 10.00 to fix. Much better than a 500.00 fuel pump. I did have to replace the fuel line that goes up to the steel line that feeds the injectors, I think it was 1/4" high pressure fuel line that I just clamped over the steel line. Works good, hopefully "Lasts long time". I'll get a picture posted of it all back together in a couple of days, I'm out of town right now.

Not pretty but it's worked for about 7 months now:


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Ok, sorry it's been so long, I hadn't forgot, I just never sat down and explained how the repair came out. I was able to get a brass elbow with a 3/8" NPT thread and a 1/4" barbed slip on fitting. The 3/8" was bigger than I wanted but all I could find. I had to go to a hose/hydraulics store to get that. I also got a piece of replacement fuel line to replace the stock line that had molded ends. I slowly drilled the hole in the top of the fuel pump bigger and bigger until I got it to just under the size of the 3/8" threaded elbow I bought. It turns out when you drill that hole out to that size, the "compartment" that it goes into in the other side of that plastic top is really narrow. When I drilled it out, the drill was slightly cutting into the walls on each side. I think this helped give the threads something more to bite into. I didn't tap the hole, I just let the threads cut their own path. With the walls on the other side, I wasn't worried about cracking it. After I threaded it in once to get threads, I pulled it out and covered the threads in JB Weld and then threaded it back in. I had scuffed up the top around the hole so more JB weld around the fitting would have a place to "grab" onto. After letting it dry, I put it back together and it hasn't leaked a drop. Cost me about 10.00 to fix. Much better than a 500.00 fuel pump. I did have to replace the fuel line that goes up to the steel line that feeds the injectors, I think it was 1/4" high pressure fuel line that I just clamped over the steel line. Works good, hopefully "Lasts long time". I'll get a picture posted of it all back together in a couple of days, I'm out of town right now.

Not pretty but it's worked for about 7 months now:

I know this is an old thread, but this just happened to me over the weekend. I'll be trying the same repair tonight. One question I have is what kind of plastic the fuel pump is? The 2 epoxies I bought both said not for use on polyethelyne or polypropylene.

Based on Ken's repair using J-B Weld for the 90* brass elbow i would be inclined to think that the mat'l is not polyethelyne or polypropylene based on the following link:

• J-B Weld Company - Frequently Asked Questions
  • J-B Weld Company - Frequently Asked Questions
    • Q: Is there anything that J-B Weld WON'T bond to?
      • A: J-B Weld will not adhere to, or bond well to:
        • Any flexible rubber surface
        • Leather
        • Vinyl
        • Canvass
        • Polypropylene plastic
        • Polyethylene plastic

*** I would suggest testing the broken pc 1st ***​

 

Very creative! Hope it works for you.

 

I just broke the same thing last night...I am pissed at myself.

 

Condrons, thanks for sharing your mishap and the happy ending. I am sure this will help others. That is the whole purpose of such forums as these.

 

good save Ken!, I'd like to have your skills in my tool box when needed!!

 

Great job

 

That actually happened a year and 3 months ago....It's never leaked a drop since. Guess I'd consider it a success....

Be careful where you tuck your PCIII.

 

Nicely done. How hard is it to move the PCIII to the tool kit side (wiring wise)?

 

quote:Originally posted by CBushmaker

Nicely done. How hard is it to move the PCIII to the tool kit side (wiring wise)?


Should reach, a lot of people removed their tool kit and put it there.

 

I know this is an old thread, but this just happened to me over the weekend. I'll be trying the same repair tonight. One question I have is what kind of plastic the fuel pump is? The 2 epoxies I bought both said not for use on polyethelyne or polypropylene.

 

Thanks, I made the repair last night, tonight I'll see how it worked.

 

looks like is could easily be HDPE or poly prop.....if its not , then its nylon

 

Go on ebay and I don't remember the seller name but he has salvage bike and is parting them out. Send him a picture to see if has the part. It could save you some money if he has them. I used them and they are pretty good.
PinWall Cycle Parts Inc items - Get great deals on Harley Davidson, Yamaha Venture Royal Star items on eBay Stores!

 

I guess I should have read further on in the thread before I posted

 

The repair worked perfectly. Cost maybe $15 total for the elbow, epoxy, fuel line and hose clamps. MUCH better than the $650 fuel pump replacement.

I was also able to do the repair while the pump was still mounted in the bike. I just had to remove the tank, seat latch bracket, and a couple other little things to make room.

Thanks condrons for the great write-up!!!

 

Wow, that does really suck man. Glad to hear you were able to fix it.

Thanks for posting, from here on out I'm always going to make sure I don't have anything hitting up against the fuel pump when I have to mess around with the battery / wires.

 

You're not the only loser!

I can't express how grateful I am for this post. I did the same thing and the dealership wanted $700 for a new pump. Less than $15 later I'm grinnin' like a Cheshire Cat!

 

I can't express how grateful I am for this post. I did the same thing and the dealership wanted $700 for a new pump. Less than $15 later I'm grinnin' like a Cheshire Cat!

how'd you fix it for 15 bucks???

 

You might want to try some Lepage 5 minute epoxy as a temporary fix till you get a new part. I had a pressure washer that froze and split that I epoxyed back together and it held for years with a few hundred PSI on it. I'm not sure how it will react with fuel though. It's worth a try.......

 

Glad it worked out for you! I'm going to move my power commander right now!!

 

Broken fuel pump - another one

Talk about bad timing, had my warrior shipped to the UAE and broke the pump while attempting to get the bike started after 6 months in storage. Question since the original nipple was not an elbow that broke off, why did you decide to use an elbow. Also will this fix reduce or increase the fuel flow into the pump or does that even matter.

Anthony

 

The reason for the elbow is to keep it from breaking off again. I push my power commander in there and I'm guessing the stress of that pushing against it is what caused it to break. With the elbow I'm able to lay the power commander on top of it.

I don't think you have to worry about fuel flow, since the pump should take as much as it needs either way.

 

I know this is an old thread, but this thread is how I actually found RSWarrior. I bought my Warrior yesterday and the owner snapped off the nipple on his fuel pump with the Power Commander while I was there looking at the bike. I still wanted the bike so we knocked some off the price and I took it. When I got home, I searched around and found this page. I just wanted to mention that I found a new fuel pump at PartZilla.com for $362.70. While I was checking out, I saw a place for a promo code so I searched and found a 5% off promo code. After free shipping and no tax, I paid $344.56 for it. Just a thought if any others out there are looking for a fuel pump. This seems to be a common thing. I took my tool kit out and mounted the power commander there. Here's the link to the fuel pump.

5PX-13907-00-00 FUEL PUMP COMP. $362.70

 

That's a good price. YSP OEM Yamaha Parts, Engine, Motor and Racing Performance Dealer Parts | Yamaha Sports Plaza wants $356 after the discount, plus shipping.

How was your experience with partzilla? I have not bought from them.

 

Can this be added to the tips and tricks section? A reminder to be aware of this issue when digging around in there would be great.

 

My repair is now a little over 4 years old with 29,000 miles and still no leak. Probably the best $15 I've spent on my Warrior!

 

Gotta love a forum that saves you money like that!