Yamaha Road Star Raider Motorcycle Forum

Raider Categories => Technical Discussion => Topic started by: dreadly on Jun 28, 2013, 12:20:42 am

Title: Fuel pump
Post by: dreadly on Jun 28, 2013, 12:20:42 am
Thought I might start a thread for the fuel pump itself. Ares posted in his thread the first time he had it replace. He mentioned these characteristics below which I am now experiencing

Here are some symptoms to watch for that could be the fuel pump:

    Trouble starting that continually gets worse over time
* I don't have any issues starting the bike
    Engine feels like it cuts out while riding
* I haven't had it feel like it will cut out
    Engine idle dropping when sitting still with clutch in or engine actually dying
* I have had this happen a few times - seems to happen on long rides
    When giving full throttle the bike does not respond immediately
* I have noticed this just today ..
    When cruising and suddenly cranking on the throttle you hear a bizarre ass noise
* I don't think I want to hear this noise
    Your gas mileage seems to increase for no reason
* gas mileage is still as expected
    Will most likely experience more decel popping/backfires
* haven't noticed any more than normal backfires

I think I may call and see how much a fuel pressor test would be. I might also try some seafoam and will try not to let the light come on anymore - I've done it a few times.

a few related threads
https://www.roadstarraider.com/index.php?topic=17226.0 (https://www.roadstarraider.com/index.php?topic=17226.0)
https://www.roadstarraider.com/index.php?topic=32393.0 (https://www.roadstarraider.com/index.php?topic=32393.0)
https://www.roadstarraider.com/index.php?topic=17068.0 (https://www.roadstarraider.com/index.php?topic=17068.0)
Title: Re: Fuel pump
Post by: CHROMINATOR on Jun 28, 2013, 01:13:52 am
Great idea Dreadly but I am hoping I will never have to come back to this thread for my own verification...  :o

Admin, maybe this thread can get a sticky...  :shrug:
Title: Re: Fuel pump
Post by: woodog on Jun 28, 2013, 06:50:00 am
With those symptoms 95%... Fuel pump going bad.....
Title: Re: Fuel pump
Post by: wolfraider on Jun 28, 2013, 07:08:48 am
After my recent experience, I can only agree.
Title: Re: Fuel pump
Post by: RedLineRick on Jun 28, 2013, 07:46:10 am
Great. I'm starting to experience a couple of those symptoms and was afraid it might be the pump going.
Title: Re: Fuel pump
Post by: wileecoyote on Jun 28, 2013, 08:14:38 am
What kind of mileage are we talking when symptoms start?
Title: Re: Fuel pump
Post by: dreadly on Jun 28, 2013, 09:02:25 am
What kind of mileage are we talking when symptoms start?

I believe:
Ares - 35k
Woodog - 31k
Wolfraider - 87k
Kewlraider - don't recall
v8_vega - don't recall
seventhLetter - don't recall
wileecoyote - Roadstar - 26k

I'm currently at 25k ... nothing has failed yet but ...................
Title: Re: Fuel pump
Post by: Ares X on Jun 28, 2013, 09:44:56 am
I went ahead and stickied this thread. 

The thing with the symptoms is that many other things can cause the same symptoms.  Each time it happened to me, I first did the Seafoam.  It would help for a day or two and then get worse. Then I'd chang plugs and clean the air filter. Again, it got better for a couple of days and then got worse.  I think Wolf and Woodog experienced similar things.  Eventually after it had already been diagnosed the second time, there were times I'd be riding along and you'd feel the engine cut out for a second.  It was usually in the afternoons. Which means it was because it was running hotter or because it was lower on fuel, since I have a full tank in the morning.   I believe Wolf experienced the loss in acceleration as well.  Correct me if I'm wrong.
Title: Re: Fuel pump
Post by: dreadly on Jun 30, 2013, 08:05:14 pm
On a ride Saturday, the bike stalled after going through two tanks of gas along with 1/2 seafoam.
Title: Re: Fuel pump
Post by: Ares X on Jul 01, 2013, 11:20:58 am
On a ride Saturday, the bike stalled after going through two tanks of gas along with 1/2 seafoam.

Are you feeling any cutting out when riding? Like a loss in HP for a moment. 
Title: Re: Fuel pump
Post by: zakattak on Jul 01, 2013, 01:22:26 pm
What about that high pitched whine when you turn the bike on.... Is that bad? if not can i get rid of that noise?
Title: Re: Fuel pump
Post by: Ares X on Jul 01, 2013, 03:18:45 pm
What about that high pitched whine when you turn the bike on.... Is that bad? if not can i get rid of that noise?

Not sure what whine you're referring to. Are you saying when you turn the key on or start the engine?
Title: Re: Fuel pump
Post by: dreadly on Jul 01, 2013, 03:20:24 pm
On a ride Saturday, the bike stalled after going through two tanks of gas along with 1/2 seafoam.

Are you feeling any cutting out when riding? Like a loss in HP for a moment.

Once or twice ... but it's done that for a few years.
Title: Re: Fuel pump
Post by: Ares X on Jul 01, 2013, 03:24:13 pm
On a ride Saturday, the bike stalled after going through two tanks of gas along with 1/2 seafoam.

Are you feeling any cutting out when riding? Like a loss in HP for a moment.

Once or twice ... but it's done that for a few years.


Really?  Only time I ever had that happen was when the fuel pump was going out.  Have you checked the plugs and air filter? Both will cause the same symptoms.
Title: Re: Fuel pump
Post by: dreadly on Jul 01, 2013, 06:44:34 pm
Once or twice ... but it's done that for a few years.


Really?  Only time I ever had that happen was when the fuel pump was going out.  Have you checked the plugs and air filter? Both will cause the same symptoms.
[/quote]

Could check the plugs ... air filter is new this year.
Title: Re: Fuel pump
Post by: Ares X on Jul 01, 2013, 06:49:31 pm
Once or twice ... but it's done that for a few years.


Really?  Only time I ever had that happen was when the fuel pump was going out.  Have you checked the plugs and air filter? Both will cause the same symptoms.

Could check the plugs ... air filter is new this year.
[/quote]

Yeah but see if you picked anything up and it's blocking the air filter.  I had a couple of bird feathers in mine once.
Title: Re: Fuel pump
Post by: dreadly on Jul 01, 2013, 08:21:57 pm
Shall do
Title: Re: Fuel pump
Post by: dreadly on Jul 02, 2013, 08:59:07 am
For those that have experienced the fuel pump issue, was it a gradual progression or a sudden problem?
Title: Re: Fuel pump
Post by: Ares X on Jul 02, 2013, 09:32:04 am
For those that have experienced the fuel pump issue, was it a gradual progression or a sudden problem?

Gradual. with the occasional total stall of the engine.
Title: Re: Fuel pump
Post by: zakattak on Jul 02, 2013, 01:47:25 pm
Im talking about turning the key and not starting the engine...when the system runs through its initial check when the key is turned the fuel pump makes a high pitched whine...every bike with a fuel pump ive ever owned does this but i would like to stop it
Title: Re: Fuel pump
Post by: Ares X on Jul 02, 2013, 01:50:02 pm
Im talking about turning the key and not starting the engine...when the system runs through its initial check when the key is turned the fuel pump makes a high pitched whine...every bike with a fuel pump ive ever owned does this but i would like to stop it

You mean that whine that lasts for about 2 seconds?  I guess I don't give it much thought. Actually I kind of like it because if I don't here it, then I assume something is wrong.
Title: Re: Fuel pump
Post by: dreadly on Jul 02, 2013, 02:02:20 pm
You mean that whine that lasts for about 2 seconds?  I guess I don't give it much thought. Actually I kind of like it because if I don't here it, then I assume something is wrong.
agreed ... just something you come to expect, and if I don't, I would panic
Title: Re: Fuel pump
Post by: Ares X on Jul 02, 2013, 02:09:13 pm
You mean that whine that lasts for about 2 seconds?  I guess I don't give it much thought. Actually I kind of like it because if I don't here it, then I assume something is wrong.
agreed ... just something you come to expect, and if I don't, I would panic

I did when I installed the LA Choppers handlebars and turned it on to test and no noise, no speedo dance, nothing. Then I remembered I had all of the wires that were normally inside the headlight disconnected.
Title: Re: Fuel pump
Post by: Paladin on Jul 02, 2013, 02:20:53 pm
For those that have experienced the fuel pump issue, was it a gradual progression or a sudden problem?
Dreadly,

If you go back and look through the posts regarding fuel pump issues, you'll find that I gave pretty detailed instructions on how to check the fuel pump and fuel regulator for problems and how to determine which one was faulty.
Title: Re: Fuel pump
Post by: dreadly on Jul 02, 2013, 03:02:04 pm
For those that have experienced the fuel pump issue, was it a gradual progression or a sudden problem?
Dreadly,

If you go back and look through the posts regarding fuel pump issues, you'll find that I gave pretty detailed instructions on how to check the fuel pump and fuel regulator for problems and how to determine which one was faulty.

On the agenda Paladin ...

For those reading this thread - Paladin's explanation on how to check fuel pressure:
Your unregulated fuel pressure (input side of the regulator) should be about 70-75 PSI. Regulated fuel pressure (output side of the regulator) needs to be 55-56 PSI. To check this, hook your pressure gauge to the output side of the regulator. Turn the key on, and read the pressure. The pressure should read 55-56 PSI. If you don't get this initial reading, you have a fuel pump problem. If you get the propper PSI reading, having turned the key on, turn the key off, and watch the pressure gauge. The pressure should hold. Eventually the pressure will drop, due to the regulator's fuel return line. However, if the pressure drops off right away, you have a regulator problem.
The Raider's stock fuel regulator isn't adjustable, either manually or through a vacuume control. 
Title: Re: Fuel pump
Post by: 102~2~113 on Jul 02, 2013, 03:36:06 pm
Subscribed.

About the Seafoam that Dreadly and Aresx added.  It sounded like you added 1/2 can or 8 oz to the tank.  with a full tank that would be twice the recommended formula, added to an empty tank and gravity fed into the reserve tank prior to filling, that could be 8+ times the recommended formula.  Could this have anything to do with the fuel pump or regulator issues?
Title: Re: Fuel pump
Post by: dreadly on Jul 02, 2013, 03:45:05 pm
Don't believe it had anything to do with my issues - I only tried this Saturday. Had it stall twice that week and once after the Seafoam addition.
Title: Re: Fuel pump
Post by: Ares X on Jul 02, 2013, 03:53:12 pm
Subscribed.

About the Seafoam that Dreadly and Aresx added.  It sounded like you added 1/2 can or 8 oz to the tank.  with a full tank that would be twice the recommended formula, added to an empty tank and gravity fed into the reserve tank prior to filling, that could be 8+ times the recommended formula.  Could this have anything to do with the fuel pump or regulator issues?

It wouldn't.   First time I ever used Seafoam I used way too much too.  I freaked out and contacted the company and he said there was nothign to worry about. He said Seafoam is oil based and will not harm the enigine.  He said you may get some blue smoke (I never did), but that would be the worst of it. 
Title: Re: Fuel pump
Post by: Ares X on Jul 02, 2013, 03:55:50 pm
For those that have experienced the fuel pump issue, was it a gradual progression or a sudden problem?
Dreadly,

If you go back and look through the posts regarding fuel pump issues, you'll find that I gave pretty detailed instructions on how to check the fuel pump and fuel regulator for problems and how to determine which one was faulty.

On the agenda Paladin ...

For those reading this thread - Paladin's explanation on how to check fuel pressure:
Your unregulated fuel pressure (input side of the regulator) should be about 70-75 PSI. Regulated fuel pressure (output side of the regulator) needs to be 55-56 PSI. To check this, hook your pressure gauge to the output side of the regulator. Turn the key on, and read the pressure. The pressure should read 55-56 PSI. If you don't get this initial reading, you have a fuel pump problem. If you get the propper PSI reading, having turned the key on, turn the key off, and watch the pressure gauge. The pressure should hold. Eventually the pressure will drop, due to the regulator's fuel return line. However, if the pressure drops off right away, you have a regulator problem.The Raider's stock fuel regulator isn't adjustable, either manually or through a vacuume control.


I believe this was the issue with mine the last time.  They told me my pressure was good and checked it a number of times.  Then they found it wasn't maintaining any pressure and finally came to the realization that I was right all along and I had a fuel pump problem.  I was thinking that mine dropped while it was running though.  Can't completely remember as it's been a while.
Title: Re: Fuel pump
Post by: wileecoyote on Jul 02, 2013, 06:56:21 pm
I was just going through my maintenance records for my other Yamaha....2006 Roadstar, and the fuel pump on that died at 26k.  I would presume different fuel pump than Raider, but just seemed to me an odd coincidence.
Title: Re: Fuel pump
Post by: michael t on Jul 02, 2013, 11:16:47 pm
Used pump on e bay  buy now  90 bucks . Might be worth buying as a back up pump 


http://www.ebay.com/itm/Yamaha-Roadliner-Stratoliner-Raider-Motorcycle-Fuel-Pump-1D7-13907-00-Used-/261236916376?pt=Motorcycles_Parts_Accessories&hash=item3cd2ef0098&vxp=mtr (http://www.ebay.com/itm/Yamaha-Roadliner-Stratoliner-Raider-Motorcycle-Fuel-Pump-1D7-13907-00-Used-/261236916376?pt=Motorcycles_Parts_Accessories&hash=item3cd2ef0098&vxp=mtr)
Title: Re: Fuel pump
Post by: CHROMINATOR on Jul 02, 2013, 11:56:09 pm
Used pump on e bay  buy now  90 bucks . Might be worth buying as a back up pump 


http://www.ebay.com/itm/Yamaha-Roadliner-Stratoliner-Raider-Motorcycle-Fuel-Pump-1D7-13907-00-Used-/261236916376?pt=Motorcycles_Parts_Accessories&hash=item3cd2ef0098&vxp=mtr (http://www.ebay.com/itm/Yamaha-Roadliner-Stratoliner-Raider-Motorcycle-Fuel-Pump-1D7-13907-00-Used-/261236916376?pt=Motorcycles_Parts_Accessories&hash=item3cd2ef0098&vxp=mtr)

The only thing I don't like about it is that it came off a 2007.  There is no telling how many miles that pump has on it and and how much remaining life it may have, if any.  The seller says "Looks to be in good condition." That does not make me feel very optimistic about it.
Title: Re: Fuel pump
Post by: dreadly on Jul 03, 2013, 08:47:04 am
I was just going through my maintenance records for my other Yamaha....2006 Roadstar, and the fuel pump on that died at 26k.  I would presume different fuel pump than Raider, but just seemed to me an odd coincidence.

added to my post on the first page ...
Title: Re: Fuel pump
Post by: Ares X on Jul 03, 2013, 09:36:06 am
I wouldn't buy a used fuel pump. 
Title: Re: Fuel pump
Post by: RangerRick on Jul 03, 2013, 09:15:15 pm
 :agree: No way No how
Title: Re: Fuel pump
Post by: woodog on Jul 04, 2013, 08:27:15 am
 :yikes: used pump, no way!
Title: Re: Fuel pump
Post by: dreadly on Jul 04, 2013, 08:38:27 am
I know I am grasping at nothing other than hope ... BUT no stalls since Saturday  :fingerscrossed:
Title: Re: Fuel pump
Post by: woodog on Jul 04, 2013, 08:51:34 am
I know I am grasping at nothing other than hope ... BUT no stalls since Saturday  :fingerscrossed:

I hope it gets better. Mines was doing the same thing but got worse, then one day would'nt start ( Fuel Pump).
I would not venture to far from home, maybe the end of your driveway at the most. IMO
Title: Re: Fuel pump
Post by: dreadly on Jul 04, 2013, 09:11:56 am
I can't wait for it to fail ... my basic plan is to not ride far without someone else. Was going to head out last Friday by myself for a day ride, but choose not to in-case it did fail. 
Title: Re: Fuel pump
Post by: mxracer546 on Jul 04, 2013, 09:24:06 am
I did find it interesting that the Fuel Pump part number 1D7-13907-00-00 in the Raider has been used since 2006 - current. It has been used in the Roadliner and Stratoliner before the Raider came around.

I try and never let the fuel light come on. My theory is that if I keep fuel in the secondary tank (fuel pump) that it helps keep it cool and maybe it will not fail. But, I have no idea!
Title: Re: Fuel pump
Post by: the urban legend on Jul 04, 2013, 06:33:53 pm
I did find it interesting that the Fuel Pump part number 1D7-13907-00-00 in the Raider has been used since 2006 - current. It has been used in the Roadliner and Stratoliner before the Raider came around.

I try and never let the fuel light come on. My theory is that if I keep fuel in the secondary tank (fuel pump) that it helps keep it cool and maybe it will not fail. But, I have no idea!
I've been doing that lately too.I used to let it light just to see how much mileage I could get from a full tank,but with all this talk about dying fuel pumps I never let the fuel gauge go lower than 1/4 tank.
Title: Re: Fuel pump
Post by: dreadly on Jul 08, 2013, 09:58:00 am
I know this has nothing to do with the fuel pump ... but I changed the transfer case oil and tightened the belt and it seems to run like a top.

Title: Re: Fuel pump
Post by: woodog on Jul 08, 2013, 12:01:41 pm
I know this has nothing to do with the fuel pump ... but I changed the transfer case oil and tightened the belt and it seems to run like a top.

No it does'nt...
Title: Re: Fuel pump
Post by: dreadly on Jul 08, 2013, 12:07:23 pm
I know this has nothing to do with the fuel pump ... but I changed the transfer case oil and tightened the belt and it seems to run like a top.

No it does'nt...
I'm waiting for the big fail still .... tick tick tick.
Going to do a 1000km/600m rip this weekend. We'll see how that ends up  ;D
Title: Re: Fuel pump
Post by: woodog on Jul 08, 2013, 01:35:53 pm
I know this has nothing to do with the fuel pump ... but I changed the transfer case oil and tightened the belt and it seems to run like a top.

No it does'nt...
I'm waiting for the big fail still .... tick tick tick.
Going to do a 1000km/600m rip this weekend. We'll see how that ends up  ;D

Did you atleast get the pump pressure checked?
Title: Re: Fuel pump
Post by: dreadly on Jul 08, 2013, 01:44:17 pm
Did you atleast get the pump pressure checked?

damn .... I now know there was something I forgot to do while I was changing oil. I shall get to that this week - thanks for the reminder
Title: Re: Re: Fuel pump
Post by: v8_vega on Jul 13, 2013, 09:37:30 am
What kind of mileage are we talking when symptoms start?

I believe:
Ares - 35k
Woodog - 31k
Wolfraider - 87k
Kewlraider - don't recall
v8_vega - don't recall
seventhLetter - don't recall
wileecoyote - Roadstar - 26k

I'm currently at 25k ... nothing has failed yet but ...................

I believe mine went out around 45k. Seems it wasn't really gradual, just started having power issues, cutting out at higher rpms and loads. Got worse as engine temp rose.
Title: Re: Fuel pump
Post by: Ares X on Aug 08, 2013, 03:43:07 pm
I was just thinking about the Fuel pump due to another thread and I wanted to post some info I've been wondering about...

Recently AZ Raider came over to pick up the stock exhaust from my Raider. He was having some weird issues with the way it was running and wanted to try an unaltered stock exhaust system.  As we were talking he mentioned he was questioning his battery as well. I still had the Shorai battery I used for literally one week and sold it to him at my cost. The symptoms he was describing to me sounded very similar to the fuel pump issue, but he only has around 17,000 miles on his Raider (I think).

A little over a week ago I get a text from him and sure enough... His fuel pump went bad.

Both times my fuel pump went out I ended up changing out the battery per the dealers recommendation. One of them I had to since it wouldn't even start for me to take home. So is there a chance that a bad battery could cause a problem with the fuel pump?  It just seems like a very strange coincidence.

Any of you who also had fuel pump issues, did you have battery issues at the same time?
Title: Re: Fuel pump
Post by: dreadly on Aug 08, 2013, 03:50:18 pm
I think my issues were due to the bushing being gone from my clutch lever. Chilli posted an article stating that this can cause issues with seems to act like a fuel pump issue.

I replaced the bushing and haven't had it stall once - I will hopefully be able to put some mile on it this weekend and see if the issue truly is gone
Title: Re: Fuel pump
Post by: KewlRaider on Aug 08, 2013, 04:10:34 pm
I didn't go back through this thread to see if it had been discussed but my feeling on my fuel pump issue is that I had a bad habit of running well into my reserve all the time.   From what i've heard it's seems that's a bad thing to do since the fuel pump is cooled by the the gasoline in which it lies.  I don't know that the problem was caused by that but it's enough for me to now not run into my reserve unless absolutely necessary.
Title: Re: Fuel pump
Post by: Capt_Zoom on Aug 08, 2013, 04:20:14 pm
I didn't go back through this thread to see if it had been discussed but my feeling on my fuel pump issue is that I had a bad habit of running well into my reserve all the time.   From what i've heard it's seems that's a bad thing to do since the fuel pump is cooled by the the gasoline in which it lies.  I don't know that the problem was caused by that but it's enough for me to now not run into my reserve unless absolutely necessary.

I've got a relative with a HD dresser and big bore setup and his bike has that problem...all of that make do.  He told me once that the last thing you wanted to do was run out of fuel in this HD.  that it caused all kinds of issues.

Not sure if running into the reserves would cause it but if your cruising on fumes a lot with barely anything left it could. 

Even with this it seems odd to me that a manufacturer would use such a fragile pump.  I run my jeeps and other vehicles to fumes regularly and have never had a fuel pump issue and that's with over 200 miles on various vehicles.  Maybe on cars the wind helps cool them where on the raider the pump isn't getting as much air.
Title: Re: Fuel pump
Post by: Ares X on Aug 08, 2013, 04:23:41 pm
I didn't go back through this thread to see if it had been discussed but my feeling on my fuel pump issue is that I had a bad habit of running well into my reserve all the time.   From what i've heard it's seems that's a bad thing to do since the fuel pump is cooled by the the gasoline in which it lies.  I don't know that the problem was caused by that but it's enough for me to now not run into my reserve unless absolutely necessary.

I've got a relative with a HD dresser and big bore setup and his bike has that problem...all of that make do.  He told me once that the last thing you wanted to do was run out of fuel in this HD.  that it caused all kinds of issues.

Not sure if running into the reserves would cause it but if your cruising on fumes a lot with barely anything left it could. 

Even with this it seems odd to me that a manufacturer would use such a fragile pump.  I run my jeeps and other vehicles to fumes regularly and have never had a fuel pump issue and that's with over 200 miles on various vehicles.  Maybe on cars the wind helps cool them where on the raider the pump isn't getting as much air.

Late model Pontiac Trans Am and late 90's Chevy Camaros were this way. I know because we ended up replacing fuel pumps in both and it was not cheap.
Title: Re: Fuel pump
Post by: michael t on Aug 08, 2013, 09:59:24 pm
 Well I will keep riding my way and we one day shall see .  I don't take long road trips  nevr more than 50 miles from home  Mainly due to health problems  So I fill up  between 90 and 110 miles  about every time.  I have never saw reserve light  and only once went just over 120 miles. . If my pump goes out not from lack of cooling gas. around pump.  But the thought of that made me buy the extended warranty.
Title: Re: Fuel pump
Post by: Paladin on Aug 10, 2013, 01:55:23 am
The reason the fuel pumps crack is because the pump is suspended from the top of the secondary fuel tank and the fuel pump doesn't receive any physical support at the bottom of the tank. This mounting arrangement makes the fuel pump prone to cracking due to vibration.
Title: Re: Fuel pump
Post by: Capt_Zoom on Aug 10, 2013, 10:52:48 am
The reason the fuel pumps crack is because the pump is suspended from the top of the secondary fuel tank and the fuel pump doesn't receive any physical support at the bottom of the tank. This mounting arrangement makes the fuel pump prone to cracking due to vibration.

Wonder if we could make a lower mount for more support.
Title: Re: Fuel pump
Post by: Ares X on Aug 12, 2013, 10:19:48 am
The reason the fuel pumps crack is because the pump is suspended from the top of the secondary fuel tank and the fuel pump doesn't receive any physical support at the bottom of the tank. This mounting arrangement makes the fuel pump prone to cracking due to vibration.

Wonder if we could make a lower mount for more support.

I would certainly think so.  It can't be all that tough and there's definitely some room to work there.
Title: Re: Fuel pump
Post by: dstaffel on Aug 14, 2013, 11:04:52 pm
so the mechanic just told me my stalls / inability to run the bike is due to failing fuel pump, at 19.5k miles! I feel scammed by yamaha but whatever. I wanted to ask if any of you have seen better performance (longevity) from the replacements or the same shit? are there any updates or options for this repair?
Title: Re: Fuel pump
Post by: Tail dragger on Aug 15, 2013, 06:34:42 am
ds, just a question.  Do you wait to fuel up when the low fuel light comes on and have you ever run out of gas?  Just wondering if low fuel can cause heat on that pump and cause premature failure?  Sure seems that less than 20,000 miles shouldn't be happening.
Title: Re: Fuel pump
Post by: Ares X on Aug 15, 2013, 10:17:16 am
AZ Raider just had it happen to him at about 20,000 miles.  I believe he bought his used, so he'd have no way to knowing the fuel history of the bike.

Mine went out right around 35,000 miles on my first fuel pump and around 70,000 on the second.  I don't think Yamaha had replaced the part # on it at this point.  I did get lucky and they paid for the second one.

My recommendation is to call Yamaha and explain your mileage and ask if this is something you should expect every 20,000 miles. You may get lucky and they may cover it. Worst case is that you wasted a phone call and some time.

I believe Wolf had over 80,000 miles before his started giving him trouble. Obviously he was doing something right.  I do think the AZ heat has something to do with mine going out.  I did run out of gas once and ran really low twice.  I try not to do that.
Title: Re: Fuel pump
Post by: dstaffel on Aug 15, 2013, 10:49:44 pm
AZ Raider just had it happen to him at about 20,000 miles.  I believe he bought his used, so he'd have no way to knowing the fuel history of the bike.

Mine went out right around 35,000 miles on my first fuel pump and around 70,000 on the second.  I don't think Yamaha had replaced the part # on it at this point.  I did get lucky and they paid for the second one.

My recommendation is to call Yamaha and explain your mileage and ask if this is something you should expect every 20,000 miles. You may get lucky and they may cover it. Worst case is that you wasted a phone call and some time.

I believe Wolf had over 80,000 miles before his started giving him trouble. Obviously he was doing something right.  I do think the AZ heat has something to do with mine going out.  I did run out of gas once and ran really low twice.  I try not to do that.

Wow so this really is the life of the bike issue thanks for the response and advice definitely gonna give em a call tomorrow. Yes generally after the fuel light is when I fill up thought that was its purpose lol Although not the day it failed me I had ridden all day but continued to fill at 1/2 tanks cause wasn't sure of the next gas location. Sorry but all this talk of babying this pump if fking BS, its a motorcycle wtf are they doing to make it so fragile? A 20k car is practically new are bike years like dog years? (honest question) Do MC owners expect more major repairs within fives years of use?
Title: Re: Fuel pump
Post by: Ares X on Aug 16, 2013, 09:24:11 am
AZ Raider just had it happen to him at about 20,000 miles.  I believe he bought his used, so he'd have no way to knowing the fuel history of the bike.

Mine went out right around 35,000 miles on my first fuel pump and around 70,000 on the second.  I don't think Yamaha had replaced the part # on it at this point.  I did get lucky and they paid for the second one.

My recommendation is to call Yamaha and explain your mileage and ask if this is something you should expect every 20,000 miles. You may get lucky and they may cover it. Worst case is that you wasted a phone call and some time.

I believe Wolf had over 80,000 miles before his started giving him trouble. Obviously he was doing something right.  I do think the AZ heat has something to do with mine going out.  I did run out of gas once and ran really low twice.  I try not to do that.

Wow so this really is the life of the bike issue thanks for the response and advice definitely gonna give em a call tomorrow. Yes generally after the fuel light is when I fill up thought that was its purpose lol Although not the day it failed me I had ridden all day but continued to fill at 1/2 tanks cause wasn't sure of the next gas location. Sorry but all this talk of babying this pump if fking BS, its a motorcycle wtf are they doing to make it so fragile? A 20k car is practically new are bike years like dog years? (honest question) Do MC owners expect more major repairs within fives years of use?

It depends on how much you ride them in 5 years.  I had 80k on mine at 4 years and Wolfraider will probably hit 100k with about 5 years. Bike years are like dog years in relation to cars.  We just don't get the same miles out of them. A bike with 40-50,000 miles on it is considered a very used bike.  Not to say it wont last, but it's not the same as cars.

Personally, I think there may be an issue with the fuel pump that Yamaha needs to address.  We just need to get enough facts and history on it to prove it to them.  Then maybe they'll change something.  I'm guessing someone there is already thinking the same thing or they wouldn't have covered my second fuel pump replacement.

With my second Raider I wanted to make sure this wouldn't be an issue, so I made sure I had a 5 year warranty on it.
Title: Re: Fuel pump
Post by: dstaffel on Aug 16, 2013, 11:04:47 am
Wow good to know thanks for the explaination Ares, it's much appreciated!
Title: Re: Fuel pump
Post by: Ares X on Aug 16, 2013, 11:13:33 am
Wow good to know thanks for the explaination Ares, it's much appreciated!

There was talk in another thread about issues with bikes and from what it sounds, even if you have the fuel pump go out, it's pretty minor compared to the headaches a lot of the other manufacturer's owners deal with.

Wolfraider ended up replacing his own. I forget how much it cost him, but he made it sound like it wasn't terribly hard to do. At the time mine went out the first time I was not even close to being comfortable attempting that.  Now I would possibly give it a try except that with the warranty it should be covered if it happens on my new one.
Title: Re: Fuel pump
Post by: dreadly on Sep 09, 2013, 04:54:06 pm
I think my issues were due to the bushing being gone from my clutch lever. Chilli posted an article stating that this can cause issues with seems to act like a fuel pump issue.

I replaced the bushing and haven't had it stall once - I will hopefully be able to put some mile on it this weekend and see if the issue truly is gone

First long run since the clutch bushing was replaced. Where I noticed the stalling before was after a long ride and having to stop. Went to run a 1/2 marathon this weekend - it was a 550km round trip. No stalling at all ...
Title: Re: Fuel pump
Post by: Ares X on Sep 12, 2013, 12:56:28 pm
I think my issues were due to the bushing being gone from my clutch lever. Chilli posted an article stating that this can cause issues with seems to act like a fuel pump issue.

I replaced the bushing and haven't had it stall once - I will hopefully be able to put some mile on it this weekend and see if the issue truly is gone

First long run since the clutch bushing was replaced. Where I noticed the stalling before was after a long ride and having to stop. Went to run a 1/2 marathon this weekend - it was a 550km round trip. No stalling at all ...

Good to hear.
Title: Re: Fuel pump
Post by: bloudie on Sep 12, 2013, 03:50:35 pm
have a good fuel pump for sale... $125 +shipping... will post as soon as I can picture it... also have entire fuel injection system up for grabs , bloudie
Title: Re: Fuel pump
Post by: AZ~Raider on Sep 12, 2013, 05:38:53 pm
My fuel pump went out after a ride into the mountains, and i did run out of fuel once 2 months prior to it failing.  :o  It failed slowly so i didn't get stranded.  I have heard altitude changes can cause it,,,,, and if you run ot of gas,,,,, and that its an 09 issue... I guess i just did them all to really be sure i needed a new one!  LOL   :P
Title: Re: Fuel pump
Post by: CHROMINATOR on Sep 13, 2013, 08:00:20 am
My fuel pump went out after a ride into the mountains, and i did run out of fuel once 2 months prior to it failing.  :o  It failed slowly so i didn't get stranded.  I have heard altitude changes can cause it,,,,, and if you run ot of gas,,,,, and that its an 09 issue... I guess i just did them all to really be sure i needed a new one!  LOL   :P

Man, that sucks but aren't the fuel pumps the same for all years?  If it is a pump issue I doubt it would be just the 09's having it.  Could very well be the running out of gas, would that include hitting the reserve?  I have hit the reserve twice but did not run out of gas...  :fingerscrossed:
Title: Re: Fuel pump
Post by: tice on Sep 13, 2013, 09:01:16 am
Man, after reading this and the problem I had a few weeks ago, I'm really considering just replacing my pump. I've never run out but I have taken it into the reserve several times. I have noticed somethng lately, when accelerating from a stop pretty hard it kinda takes a second for it to really start pulling, almost like turbo lag. :shrug:
Title: Re: Fuel pump
Post by: AZ~Raider on Sep 19, 2013, 09:00:38 am
Man, after reading this and the problem I had a few weeks ago, I'm really considering just replacing my pump. I've never run out but I have taken it into the reserve several times. I have noticed somethng lately, when accelerating from a stop pretty hard it kinda takes a second for it to really start pulling, almost like turbo lag. :shrug:
TRhats how mone started,,, seamed like an air filter or old carb starving for gas.  then got worse......Good luck!  8)
Title: Re: Fuel pump
Post by: tice on Sep 19, 2013, 10:02:59 am
Its been about 300 miles since it acted up and hasn't since that day. Hard part is being able to convince my wife I need to replace it. Lol
Title: Re: Fuel pump
Post by: Ares X on Sep 19, 2013, 10:06:57 am
Its been about 300 miles since it acted up and hasn't since that day. Hard part is being able to convince my wife I need to replace it. Lol

Why do you want to replace it before it's truly failing?  Mine was a slow process both times.
Title: Re: Fuel pump
Post by: tice on Sep 19, 2013, 12:57:37 pm
Piece of mind I guess. Just don't wanna get stranded some where. I have tow insurance though. But since it hasn't acted up lately I don't know if its even the problem, though it seems like it.
Title: Re: Fuel pump
Post by: v8_vega on Oct 31, 2013, 06:19:43 pm
Since I now own a 2007 Roadliner I've been lurking on some other forums. If I can find it, someone has figured out a way to replace with a cheaper automotive pump. I'll dig around and try to provide a link.

Yall should check out some of the Roadliner/Stratoliner sites, lots of cool info that will work for our Raiders not discussed here.

Found it. http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&msg=27822.1 (http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&msg=27822.1)
Title: Re: Fuel pump
Post by: Petey_08 on Jul 03, 2014, 09:31:18 pm
I know this is an old thread, but it was at the top of the list so I decided to add it here. I made a video of the removal process for the fuel pump, something that I wasn't able to find myself.

http://youtu.be/jKaqwBeV1Vw

*UPDATE*
The patch eventually failed, so don't try it at home. Best bet is to plastic weld.
Title: Re: Fuel pump
Post by: tice on Jul 03, 2014, 09:35:17 pm
I know this is an old thread, but it was at the top of the list so I decided to add it here. I made a video of the removal process for the fuel pump, something that I wasn't able to find myself. I repaired the crack, the method I used has lasted about 800 miles so far. I have pulled it recently and the patch is holding strong. Here is the link to my video

http://youtu.be/jKaqwBeV1Vw

Petey
Damn, wish you had posted this a week ago!!
Title: Re: Fuel pump
Post by: tice on Jul 03, 2014, 09:49:26 pm
Btw, that was the exact same spot mine was cracked!!!! If you havent, you need to call Yamaha and let them know about it. They tell me they have never heard of these pumps cracking.
Title: Re: Fuel pump
Post by: Fj_Ohio on Jul 03, 2014, 09:59:13 pm
Excellent video! Very nicely done and and great advice. Thank you!
Title: Re: Fuel pump
Post by: Phaedrus on Jul 04, 2014, 05:13:36 am
Thank you Petey_08!! great video!
Title: Re: Fuel pump
Post by: Tail dragger on Jul 04, 2014, 06:29:07 am
Again...thanks for the video.
Title: Re: Fuel pump
Post by: Petey_08 on Jul 04, 2014, 08:59:01 am
I was hoping the video could help at least one person, if they could get through my accent (I'm originally from Ohio but have lived in the south for a few years, I couldn't help laughing and poking fun at myself at how thick it has become). I have heard of people trying to epoxy the crack with no luck, but just epoxy won't work because of the pressure. The repair kit was from autozone, it cost 15 bucks with tax and was the only one with a pressure rating. From my little experience, I would say the housing is made of an ABS plastic, based on the way it sanded as well as the lack of sheen (didn't do a burn test like I should have). If it isn't one of the poly plastics then the patch should hold longer than the pump.
As far as the cracking goes, the owner said he heard a woosh noise after bumping the throttle. This leads me to believe that the quick increase of pressure in the housing actually caused the rupture rather than heat or vibration. ABS is rather heat and vibration resistant, which is why a lot of radiators and other engine components are made out of it. My radiator deals with temps above 200 degrees, if your fuel is at that temp then you have more serious problems to worry about than your pump.
Title: Re: Fuel pump
Post by: Ares X on Jul 07, 2014, 10:23:06 am
I haven't had a chance to check it out yet, but thanks for posting the video.
Title: Re: Fuel pump
Post by: RonKy on Aug 06, 2014, 07:11:48 am
I called Yamaha USA and was told by a guy named Brad that they have never heard of this problem with the fuel pump.  He said they have experts that constantly troll the internet looking for problems like this. 
The same guy told my friend the exact same thing about his third gear going out also.
Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 06, 2014, 07:28:14 am
I called Yamaha USA and was told by a guy named Brad that they have never heard of this problem with the fuel pump.  He said they have experts that constantly troll the internet looking for problems like this. 
The same guy told my friend the exact same thing about his third gear going out also.

It would appear that Yamaha USA needs some new experts...  :o
Title: Re: Fuel pump
Post by: Ares X on Aug 06, 2014, 09:19:40 am
I called Yamaha USA and was told by a guy named Brad that they have never heard of this problem with the fuel pump.  He said they have experts that constantly troll the internet looking for problems like this. 
The same guy told my friend the exact same thing about his third gear going out also.

I just posted this in your other thread, but this guy is an idiot.  Ask them why Yamaha paid for the second fuel pump to go bad in my '09 Raider if they had never heard of it. 

Did you point him to this thread?
Title: Re: Fuel pump
Post by: tice on Aug 06, 2014, 09:20:15 am
I am almost certain I talked to Brad as well!!!!!!!
Title: Re: Fuel pump
Post by: RonKy on Aug 06, 2014, 12:16:34 pm
I offered to forward some links to those 'experts'  but he didn't want to hear it.  He just wanted to hang up.  The WORST customer service imaginable.  Brad's the end of the line too.  They won't even give you an address, phone number, another person to talk too, or anything.  Total jerks!  I really didn't expect any help with the part when I called, because of my mileage,  but I just don't appreciate the dishonesty.  "There's never been a call nor have we ever heard of any problem of that nature that we are aware of." The guy probably says it in his sleep.
Title: Re: Fuel pump
Post by: Ares X on Aug 06, 2014, 12:19:44 pm
I offered to forward some links to those 'experts'  but he didn't want to hear it.  He just wanted to hang up.  The WORST customer service imaginable.  Brad's the end of the line too.  They won't even give you an address, phone number, another person to talk too, or anything.  Total jerks!  I really didn't expect any help with the part when I called, because of my mileage,  but I just don't appreciate the dishonesty.  "There's never been a call nor have we ever heard of any problem of that nature that we are aware of." The guy probably says it in his sleep.

I would seriously call back a few times and see if you get someone else.  This guy could just be a jerk or suck at his job or both. Did you tell him you'd like to speak to his supervisor. That has helped me in the past with other companies.
Title: Re: Fuel pump
Post by: RonKy on Aug 07, 2014, 06:49:27 am
He is the supervisor.  No, it was the end of discussion.  I got the pump out yesterday evening and it had a 1 3/4" crack in it. 
Title: Re: Fuel pump
Post by: t84a on Aug 07, 2014, 06:57:41 am
Are you going to fix it or replace it?
Title: Re: Fuel pump
Post by: RonKy on Aug 07, 2014, 07:04:28 am
Replace.  Ordered the pump and o-ring for 438.00 through Stadium Yamaha.  I figured if the original can't hold up to the pressure a patch job won't either.  Sure didn't want to do it but hopefully the new one will last another 74,000.  The other side of that pump looks reinforced but the side with the crack isn't.
Title: Re: Fuel pump
Post by: Ares X on Aug 07, 2014, 11:57:33 am
Replace.  Ordered the pump and o-ring for 438.00 through Stadium Yamaha.  I figured if the original can't hold up to the pressure a patch job won't either.  Sure didn't want to do it but hopefully the new one will last another 74,000.  The other side of that pump looks reinforced but the side with the crack isn't.

Actually getting 74,000 miles out of it seems pretty reasonable to me.  You got twice what I did out of my first Raider.
Title: Re: Fuel pump
Post by: tice on Aug 07, 2014, 09:00:00 pm
That's the same area where mine and I'm assuming all others cracked. Pretty damn crappy customer service on Yamahas part.
Title: Re: Fuel pump
Post by: Paladin on Aug 08, 2014, 05:23:40 am
If that's the area that cracks on everyone's fuel pump, you might think about adding a re-enforcing patch to that area on your new pump, before you install it.
Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 08, 2014, 05:31:58 am
If that's the area that cracks on everyone's fuel pump, you might think about adding a re-enforcing patch to that area on your new pump, before you install it.

That's a great idea, what would be best to use for a patch?
Title: Re: Fuel pump
Post by: BK on Aug 08, 2014, 05:43:45 am
If that's the area that cracks on everyone's fuel pump, you might think about adding a re-enforcing patch to that area on your new pump, before you install it.

That's a great idea, what would be best to use for a patch?

This is the product that the guy in the video used to repair the crack.
http://www.autozone.com/autozone/accessories/VersaChem-1-06-oz-plastic-gas-tank-and-radiator-repair-kit/_/N-259t?itemIdentifier=382799_0_0_
Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 08, 2014, 05:52:17 am
If that's the area that cracks on everyone's fuel pump, you might think about adding a re-enforcing patch to that area on your new pump, before you install it.

That's a great idea, what would be best to use for a patch?

This is the product that the guy in the video used to repair the crack.
http://www.autozone.com/autozone/accessories/VersaChem-1-06-oz-plastic-gas-tank-and-radiator-repair-kit/_/N-259t?itemIdentifier=382799_0_0_

I know but Paladin is talking about putting a reinforcing patch on that side of the pump that it appears everyone is getting the crack.  I am asking what to use for that reinforcing patch.
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 07:14:27 am
Same stuff.
Title: Re: Fuel pump
Post by: RangerRick on Aug 08, 2014, 07:41:46 am
But you can't buy it on line. WTF is up with that.

from the item description online: This item cannot be shipped to any US State, US Territory or US Military address.

Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 08, 2014, 08:08:23 am
But you can't buy it on line. WTF is up with that.

from the item description online: This item cannot be shipped to any US State, US Territory or US Military address.

You can get it in the states.  I just created an account with Auto Zone, copied and pasted the name of the item, (VersaChem/1.06 oz. plastic gas tank and radiator repair kit) in the search for the local Auto Zone in my city and it popped up as not found but a Fuel tank/Radiator alternative popped up.  I clicked on it and low and behold VersaChem/1.06 oz. plastic gas tank and radiator repair kit came up and is available for in store pick up only and showing In Stock..  Was still $12.99.  I ordered it and can pick it up at my local Auto Zone today after I get off work.
Title: Re: Fuel pump
Post by: Ares X on Aug 08, 2014, 10:28:52 am
So how about everyone that had the same crack in their fuel pump send a pic to Yamaha so they can see there's a flaw in it.

Unfortunately I did not repair mine, so I never actually saw it in person.
Title: Re: Fuel pump
Post by: Tail dragger on Aug 08, 2014, 10:45:14 am
So how about everyone that had the same crack in their fuel pump send a pic to Yamaha so they can see there's a flaw in it.

Unfortunately I did not repair mine, so I never actually saw it in person.

Sounds like a good idea...then maybe they wouldn't say they never heard of the problem.
Title: Re: Fuel pump
Post by: BK on Aug 08, 2014, 10:48:42 am
So how about everyone that had the same crack in their fuel pump send a pic to Yamaha so they can see there's a flaw in it.

Unfortunately I did not repair mine, so I never actually saw it in person.

I agree but it needs be go higher up the chain than just average customer service employee.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 12:58:10 pm
DON'T BUY WHAT I SUGGESTED. Trying to get everyone to hear that. So let me repeat, DON'T BUY THE PATCHWORK FROM AUTOZONE. Just and update, my patch eventually failed (not because of pressure but because it didn't bond to the plastic, the whole patch was just sitting at the bottom of the tank). Ok, I'm out 15 bucks (not really, had 20 bucks on my rewards card), but learned a valuable lesson, the housing is not an ABS plastic but rather a poly plastic (had to do a burn test on that one, I still may be wrong but it is highly likely). So, now that we know no chemical will bond to it, we have to take a different route. Here is what I did to solve the problem (no video or pictures of this one, I know  ttiwwp). I took the fuel pump out of the housing, drained all of the fuel from it and started to look. On the other side of the housing where the crack is shown, there is about a 1"x1" piece of plastic that has no purpose, other than covering the actual pump. I cut that piece of plastic off and then welded a patch over the cracked area using it as a filler. The benefit of doing this is you have the exact same plastic so it is about the strongest patch you can get. I just used an old soldering iron that I had laying around to do the job and it only took me about an hour to pull the pump, patch it, put it back in and ride off into the sunset. So, I repeat again, DON'T GET THE PATCH I SUGGESTED THE FIRST TIME.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 01:01:22 pm
Replace.  Ordered the pump and o-ring for 438.00 through Stadium Yamaha.  I figured if the original can't hold up to the pressure a patch job won't either.  Sure didn't want to do it but hopefully the new one will last another 74,000.  The other side of that pump looks reinforced but the side with the crack isn't.
Now that I gave away some of my secrets, what are you going to do with your old pump? I would love to have a spare in the garage!
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 01:03:20 pm
Do you mean you just used a soldering iron to melt the plastic into the crack?


DON'T BUY WHAT I SUGGESTED. Trying to get everyone to hear that. So let me repeat, DON'T BUY THE PATCHWORK FROM AUTOZONE. Just and update, my patch eventually failed (not because of pressure but because it didn't bond to the plastic, the whole patch was just sitting at the bottom of the tank). Ok, I'm out 15 bucks (not really, had 20 bucks on my rewards card), but learned a valuable lesson, the housing is not an ABS plastic but rather a poly plastic (had to do a burn test on that one, I still may be wrong but it is highly likely). So, now that we know no chemical will bond to it, we have to take a different route. Here is what I did to solve the problem (no video or pictures of this one, I know  ttiwwp). I took the fuel pump out of the housing, drained all of the fuel from it and started to look. On the other side of the housing where the crack is shown, there is about a 1"x1" piece of plastic that has no purpose, other than covering the actual pump. I cut that piece of plastic off and then welded a patch over the cracked area using it as a filler. The benefit of doing this is you have the exact same plastic so it is about the strongest patch you can get. I just used an old soldering iron that I had laying around to do the job and it only took me about an hour to pull the pump, patch it, put it back in and ride off into the sunset. So, I repeat again, DON'T GET THE PATCH I SUGGESTED THE FIRST TIME.
Title: Re: Fuel pump
Post by: BK on Aug 08, 2014, 01:48:59 pm
Do a google search for plastic welding there are some videos on it, and yes you can use a soldering iron to do it.
Title: Re: Fuel pump
Post by: Ares X on Aug 08, 2014, 01:54:12 pm
So now Bill is stuck with a patch kit (that I'm not sure what he bought it for anyway) is never going to be able to use.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 04:24:27 pm
Do you mean you just used a soldering iron to melt the plastic into the crack?


DON'T BUY WHAT I SUGGESTED. Trying to get everyone to hear that. So let me repeat, DON'T BUY THE PATCHWORK FROM AUTOZONE. Just and update, my patch eventually failed (not because of pressure but because it didn't bond to the plastic, the whole patch was just sitting at the bottom of the tank). Ok, I'm out 15 bucks (not really, had 20 bucks on my rewards card), but learned a valuable lesson, the housing is not an ABS plastic but rather a poly plastic (had to do a burn test on that one, I still may be wrong but it is highly likely). So, now that we know no chemical will bond to it, we have to take a different route. Here is what I did to solve the problem (no video or pictures of this one, I know  ttiwwp). I took the fuel pump out of the housing, drained all of the fuel from it and started to look. On the other side of the housing where the crack is shown, there is about a 1"x1" piece of plastic that has no purpose, other than covering the actual pump. I cut that piece of plastic off and then welded a patch over the cracked area using it as a filler. The benefit of doing this is you have the exact same plastic so it is about the strongest patch you can get. I just used an old soldering iron that I had laying around to do the job and it only took me about an hour to pull the pump, patch it, put it back in and ride off into the sunset. So, I repeat again, DON'T GET THE PATCH I SUGGESTED THE FIRST TIME.

It was a hairline crack, so I used the soldering iron to melt the crack back together and then used that 1x1 piece I cut off and melted it over top. You have to melt all of the filler (the 1x1) and the crack so they 'flow' together. I ended up with just a huge hump over the crack, about a half inch wide.

So now Bill is stuck with a patch kit (that I'm not sure what he bought it for anyway) is never going to be able to use.

Autozone takes returns. My store had it in stock, which is why I tried it.
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 04:26:57 pm
Can you provide a little more info? Did you drill holes at the ends of the crack?
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 04:29:50 pm
Can you provide a little more info? Did you drill holes at the ends of the crack?

No. Don't drill any wholes.
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 04:51:57 pm
Can you provide a little more info? Did you drill holes at the ends of the crack?

No. Don't drill any wholes.

Well that's pretty standard practice when repairing cracks in plastic. That's why I asked. I think that holes should be drilled.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 05:20:55 pm
Can you provide a little more info? Did you drill holes at the ends of the crack?

No. Don't drill any wholes.

Well that's pretty standard practice when repairing cracks in plastic. That's why I asked. I think that holes should be drilled.

Your right, the holes stop the crack from spreading. Though, I've never seen it done, nor done it myself, when it was welded. I did the same thing on a radiator flange on my car until the new one I had to order came in. 75,000 miles later I still haven't had to install the new one. If my pump fails, I'll just take it out and do it again, I'm not worried about it, I'm telling others of what I did, if you want holes, put some holes in it.
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 05:23:48 pm
Sorry. I wasn't trying to criticize your repair. It looks that way but I didn't mean to. I have a local plastic mfg near me and a bad fuel pump from a member here. I'm going to head up there next week and pick their brain. I think they can fix one of my spare windshields as well.  Again, sorry about that Petey.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 05:31:03 pm
That is the worst part about putting words on paper (or the screen), the tone doesn't go with them. I wasn't trying to be defensive (though, after rereading it I can totally see that now). I also see I was being demanding earlier when I said "don't", I meant "didn't" No, I didn't put any holes. I'm also trying to point out if you think there is a better way to do it, then do it that way, I am just giving people other options than paying 500 for a new one.
Title: Re: Fuel pump
Post by: tice on Aug 08, 2014, 08:23:00 pm
Thanks for the update on welding it. I think I may do that with my old one some day soon. I like Dan's idea of sending them the pics, I searched last night for a while trying to find an email ( I wanted to send them a email about whats happening with the pumps) but failed to find any. Does anyone know if there is one?
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 08:24:19 pm
Use their Facebook page.
Title: Re: Fuel pump
Post by: tice on Aug 08, 2014, 08:26:14 pm
Use their Facebook page.
Hell, didnt think of that!!! Lol. Thanks.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 08, 2014, 08:27:46 pm
Use their Facebook page.
That is an awesome idea!! We should all do it and make this problem very public. 
Title: Re: Fuel pump
Post by: t84a on Aug 08, 2014, 08:32:51 pm
https://www.roadstarraider.com/index.php?topic=67657.0
Title: Re: Fuel pump
Post by: RuneRaider on Aug 08, 2014, 10:34:39 pm
Can you provide a little more info? Did you drill holes at the ends of the crack?

No. Don't drill any wholes.

Well that's pretty standard practice when repairing cracks in plastic. That's why I asked. I think that holes should be drilled.

Same with aluminum. Airframes used to stop drill aircraft panels to stop the crack from spreading as a temp fix until the plane went in for full repair. Works pretty trick.
Title: Re: Fuel pump
Post by: BlazingRaider on Aug 08, 2014, 10:58:29 pm
Can you provide a little more info? Did you drill holes at the ends of the crack?

No. Don't drill any wholes.

Well that's pretty standard practice when repairing cracks in plastic. That's why I asked. I think that holes should be drilled.

Same with aluminum. Airframes used to stop drill aircraft panels to stop the crack from spreading as a temp fix until the plane went in for full repair. Works pretty trick.

I was taught to do the same when I did my own windshield repair. Drilled holes at the end of the cracks and filled the hole. Crack stopped spreading.
Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 09, 2014, 12:10:40 am
Anybody need a brand new unused patch kit?...  :rotfl: :rotfl: :rotfl: :rotfl: :rotfl:  Thank goodness it was only $15.xx after tax.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 09, 2014, 07:41:04 am
Anybody need a brand new unused patch kit?...  :rotfl: :rotfl: :rotfl: :rotfl: :rotfl:  Thank goodness it was only $15.xx after tax.

Now your making me feel bad Bill  :-[ But you could just poke a hole in your radiator an use it.

I've also been thinking about the hole drilling in the fuel pump. I really didn't think of it when I was doing it because I was really just looking for a quick fix to get me through until I could get a new one. However, I'm not sure I would drill a hole in there. There are going to be shavings that get inside the pump, and there is no easy way to clean it out. I wouldn't want those shavings making it to the fuel injectors and clogging them up.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 09, 2014, 11:03:20 am
So just so I am clear...crystal even...the part that is wiping out the fuel pumps is a plastic housing? Is this part pressurized or just part of the suction intake system? Is it dying due to age or a combination of age and vibration. My warranty is going to expire next year and I'm not anywhere close to the mileage of those who are having problems with these. Trying to figure if mine is slowly dying while it rests or if I'll get some mileage out of the darn thing. Had a full service done this spring and it runs fine but now it's back to a tank of stabil.

Not sure if I can get an additional warranty like some are doing on other brands. While it'll cost a god chunck of change to add on, the other company will allow additional as long as it's 12yrs old or newer and less than 75,000 miles on the clock. All part of the fun of working overseas and not riding it. We'll see if Mother Yammie has any options.
Title: Re: Fuel pump
Post by: t84a on Aug 09, 2014, 11:07:12 am
The pressurized part. The actual pump is fine. The system isn't able to maintain adequate pressure with the crack in the plastic.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 09, 2014, 11:13:56 am
Anybody need a brand new unused patch kit?...  :rotfl: :rotfl: :rotfl: :rotfl: :rotfl:  Thank goodness it was only $15.xx after tax.

Now your making me feel bad Bill  :-[ But you could just poke a hole in your radiator an use it.

I've also been thinking about the hole drilling in the fuel pump. I really didn't think of it when I was doing it because I was really just looking for a quick fix to get me through until I could get a new one. However, I'm not sure I would drill a hole in there. There are going to be shavings that get inside the pump, and there is no easy way to clean it out. I wouldn't want those shavings making it to the fuel injectors and clogging them up.

Felt the same way when putting a EGT sensor in the manifold of my pickup. I put grease on the bit and also ran a vacuum cleaner during and then ran a small tube inside afterwards. Didn't want anything making it to the turbo. If you decide to do the holes you could almost turn the bit by hand and get a nice one piece curl of shavings. Not sure how brittle this plastic is but is there an area you can test on? Just thinking of options for you and anyone else trying to repair these.

They sell a plastic weld kit on Amazon and it has a couple of different types of plastic with it and I think they mention how to determine what type of plastic is in use. Was going to try and repair my RV black and grey water tanks but they're so tore up I doubt they'd hold. Too bad we can't purchase one kit for the group but how would accountability work out. Most are trustworthy but....
Title: Re: Fuel pump
Post by: Ares X on Aug 09, 2014, 11:15:11 am
Which I would guess is due to heat.   We have the same issues in AZ because of the plastc liners inside car radiators. The old style metal radiators were never an issue, but the plastic version that are used today crack a lot and I've been told countless times by mechanics is it's due to heat.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 09, 2014, 11:16:02 am
The pressurized part. The actual pump is fine. The system isn't able to maintain adequate pressure with the crack in the plastic.

Ok, gotta gotcha (f'n auto correct). Didn't know if it was just sucking air or pushing fuel back into the tank. Sounds like the later and that would mean a better grade of patch work. Thx.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 09, 2014, 11:17:26 am
Which I would guess is due to heat.   We have the same issues in AZ because of the plastc liners inside car radiators. The old style metal radiators were never an issue, but the plastic version that are used today crack a lot and I've been told countless times by mechanics is it's due to heat.

Ok, that helps some. Thx Dan.
Title: Re: Fuel pump
Post by: BK on Aug 09, 2014, 04:15:16 pm
Anybody need a brand new unused patch kit?...  :rotfl: :rotfl: :rotfl: :rotfl: :rotfl:  Thank goodness it was only $15.xx after tax.

Sorry for the bad info Bill  :-[
Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 10, 2014, 02:03:24 am
Anybody need a brand new unused patch kit?...  :rotfl: :rotfl: :rotfl: :rotfl: :rotfl:  Thank goodness it was only $15.xx after tax.

Sorry for the bad info Bill  :-[

Not a problem Bro, I was perplexed about the not able to be shipped to US or it's territories and being me just had to test it and prove it wrong...  :rotfl: :rotfl: :rotfl:  I am sure I will find a use for it.
Title: Re: Fuel pump
Post by: RonKy on Aug 11, 2014, 10:00:04 am
Interesting to see if the weld holds.  I just don't think any patchwork on this pump will last.  Be nice if it did.  If it was a plastic cup...yeah, but something pressurized, I can't see it happening.  Yamaha/Mitsubishi needs to lick their calf over on this one.
 
Title: Re: Fuel pump
Post by: Ares X on Aug 11, 2014, 10:01:11 am
Interesting to see if the weld holds.  I just don't think any patchwork on this pump will last.  Be nice if it did.  If it was a plastic cup...yeah, but something pressurized, I can't see it happening.  Yamaha/Mitsubishi needs to lick their calf over on this one.

WHAT?!?!?
Title: Re: Fuel pump
Post by: tice on Aug 11, 2014, 11:38:21 am
I finally got a response back from Yamaha's facebook page, they wanted my SR #, but didnt remember it. I told him about the website and of the others having the same problem. We will see if it goes anywhere from there.
Title: Re: Fuel pump
Post by: Ares X on Aug 11, 2014, 11:42:34 am
I finally got a response back from Yamaha's facebook page, they wanted my SR #, but didnt remember it. I told him about the website and of the others having the same problem. We will see if it goes anywhere from there.

What's an SR#?
Title: Re: Fuel pump
Post by: tice on Aug 11, 2014, 11:53:19 am
Service request. They just gave me a new number and said to call em back again. Dont know why, I've already replaced mine. Ill call anyways.
Title: Re: Fuel pump
Post by: RonKy on Aug 12, 2014, 02:43:20 pm
Ares X,  Just an old hillbilly term meaning they need to take care of their problem/creation until they get it right.
Title: Re: Fuel pump
Post by: Ares X on Aug 12, 2014, 06:15:39 pm
Ares X,  Just an old hillbilly term meaning they need to take care of their problem/creation until they get it right.

Ah!  Moved from Tennessee when I was 5 and can't say I remember much of it.
Title: Re: Fuel pump
Post by: alludc on Aug 18, 2014, 11:09:02 pm

    Trouble starting that continually gets worse over time

    Engine feels like it cuts out while riding

    Engine idle dropping when sitting still with clutch in or engine actually dying

    When giving full throttle the bike does not respond immediately

    When cruising and suddenly cranking on the throttle you hear a bizarre ass noise

    Your gas mileage seems to increase for no reason

    Will most likely experience more decel popping/backfires



SONOFABITCH!!!!  I literally have all of the above.  09, 14k miles. WTF.  How broke is this gonna make me?
Title: Re: Fuel pump
Post by: Fiddles on Aug 19, 2014, 05:40:14 am
Anywhere from 420 to 600 bucks depending on where you get the pump and don't forget the gasket
Title: Re: Fuel pump
Post by: ladrox on Aug 19, 2014, 08:15:24 am
Can someone give me the Yamaha phone # and I will try again to get them to listen and document MY fuel pump.
Title: Re: Fuel pump
Post by: Ares X on Aug 19, 2014, 09:26:42 am
This is what's on the website:

          Star Motorcycles Customer Relations
                  (800) 656-7695   


Feel free to mention my '09 Raider needing new ones at 35,000 and 70,000 miles and Yamaha paid to have the second one replaced.
Title: Re: Fuel pump
Post by: RonKy on Aug 19, 2014, 12:41:35 pm
Fuel pump was delivered to the house yesterday evening and I got it in and running last night.  Same old fuel pump as the last one. Another crack and another four or five hundred bucks just waiting to happen!
Title: Re: Fuel pump
Post by: RuneRaider on Aug 19, 2014, 01:47:11 pm
Glad you got the new pump but I hope you get better mileage out of the second one.


YAMAHA, wake the F up and fix this. You still have a much better reliability record than H-D or BMW but between the fuel pump, lifters and oil leaks you're starting to slip. 100% perfection isn't possible no matter how hard you try. Step up and fix the few problems that arise.

Doubt they'll read this but hey I feel better anyway.
Title: Re: Fuel pump
Post by: alludc on Aug 19, 2014, 02:55:31 pm
anyone have pics of their cracked pump?
Title: Re: Fuel pump
Post by: tice on Aug 19, 2014, 03:05:49 pm
I do, but its too large to post.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 19, 2014, 03:43:21 pm
Can you use MS Paint to reduce the size and focus on the crack? PM me you email or I can send you mine if not.
Title: Re: Fuel pump
Post by: t84a on Aug 19, 2014, 03:45:14 pm
Here you go. ladrox sent me his.
Title: Re: Fuel pump
Post by: alludc on Aug 19, 2014, 03:55:11 pm
that slit on the left side?
Title: Re: Fuel pump
Post by: alludc on Aug 19, 2014, 03:58:14 pm
ron hicks from the yamaha FB page showed crack in exact spot.  maybe its the same guy or maybe its the weak part of the pump

Title: Re: Fuel pump
Post by: tice on Aug 19, 2014, 04:33:40 pm
Same place as mine.
Title: Re: Fuel pump
Post by: tice on Aug 19, 2014, 04:47:02 pm
allduc, did you get my email?
Title: Re: Fuel pump
Post by: Petey_08 on Aug 19, 2014, 04:47:59 pm
That is where I think almost everyone's is.
Title: Re: Fuel pump
Post by: alludc on Aug 19, 2014, 05:05:28 pm
That is where I think almost everyone's is.

so, we have a known, documented problem with a weak point in the fuel pump and Yamaha says they are 'not aware' of an issue?

what about the Roadie & Strat guys...same pump, no?

3 different pump pics attached



Message from Yamaha on FB...
Hello Todd, we sincerely apologize for any inconvenience you have experienced associated with our product. We place high value on each customer and always welcome hearing from you. We want to give your situation the full consideration it deserves. We believe that speaking with you on the telephone will help us more fully respond to your concerns. Please kindly contact Customer Service Group at 1-800-962-7926 and kindly refer to SR # xxx Thank you.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 19, 2014, 05:20:46 pm
That is where I think almost everyone's is.

so, we have a known, documented problem with a weak point in the fuel pump and Yamaha says they are 'not aware' of an issue?

what about the Roadie & Strat guys...same pump, no?

3 different pump pics attached

Yes, the Liner has the same pump, but I haven't heard it being a problem for the Liners. I haven't been active in those forums for a while, but glossing over them I have only seen a few problems with the actual pump, and not a crack in the housing.
Title: Re: Fuel pump
Post by: t84a on Aug 19, 2014, 06:15:17 pm
That is where I think almost everyone's is.

so, we have a known, documented problem with a weak point in the fuel pump and Yamaha says they are 'not aware' of an issue?

what about the Roadie & Strat guys...same pump, no?

3 different pump pics attached



Message from Yamaha on FB...
Hello Todd, we sincerely apologize for any inconvenience you have experienced associated with our product. We place high value on each customer and always welcome hearing from you. We want to give your situation the full consideration it deserves. We believe that speaking with you on the telephone will help us more fully respond to your concerns. Please kindly contact Customer Service Group at 1-800-962-7926 and kindly refer to SR # xxx Thank you.

I posted a link to this thread on their FB page. Ask them if they have read it.
Title: Re: Fuel pump
Post by: tice on Aug 19, 2014, 07:35:22 pm
I know of one Liner pump that was just replaced, he had YES  so I dont know if it was cracked, dealer said they sent the pump back to Yamaha.
Title: Re: Fuel pump
Post by: RonKy on Aug 20, 2014, 07:06:46 am
I got my best price at the time from Stadium Yamaha for 414.26 with 15.48 shipping.  It's between Yamahapart.com, Babbits, Partzilla and Stadium.  Even with shipping, Stadium was the cheapest this time asthey are not always cheaper.  I always check and compare between these four.  I went ahead and ordered the O-ring, the Damper ring with it.  One would think for 400 bucks those things would come with it.
Title: Re: Fuel pump
Post by: ladrox on Aug 20, 2014, 07:39:32 am
ron hicks from the yamaha FB page showed crack in exact spot.  maybe its the same guy or maybe its the weak part of the pump

Mine was identical as well. Sent it to t84a in hopes he can come up with a fix.....

On the phone with Yami now...

Well, she took my info and "turned me over to a product specialist"...was on "ignore" for 15 minutes before givin up.
Title: Re: Fuel pump
Post by: alludc on Aug 20, 2014, 12:00:08 pm
Facebook version of Yamaha has been very responsive to me so far.  Im hoping they continue via the phone call im about to have
Title: Re: Fuel pump
Post by: Ares X on Aug 20, 2014, 12:01:20 pm
Facebook version of Yamaha has been very responsive to me so far.  Im hoping they continue via the phone call im about to have

Feel free to give them my name of someone who has multiple pumps fail.

GOOD LUCK!!!
Title: Re: Fuel pump
Post by: alludc on Aug 20, 2014, 12:17:36 pm
was basically given a big fat FU.

said "thanks for letting us know. we have no prior knowledge of similar issues.  We will report it to the factory though".

I asked what it is going to take for a recall to happen.  "recalls will only happen for safety reasons, a poor performing bike out of warranty because of a drop in fuel pressure will not be a candidate for recall"

Title: Re: Fuel pump
Post by: seventhLetter on Aug 20, 2014, 12:19:08 pm
I also had my fuel pump fail. Same thing. Cracked. Cost me $1000 to have dealer replace it (parts and labor)
Title: Re: Fuel pump
Post by: Ares X on Aug 20, 2014, 12:21:48 pm
was basically given a big fat FU.

said "thanks for letting us know. we have no prior knowledge of similar issues.  We will report it to the factory though".

I asked what it is going to take for a recall to happen.  "recalls will only happen for safety reasons, a poor performing bike out of warranty because of a drop in fuel pressure will not be a candidate for recall"

No prior knowledge???  Did you tell them to look at their FB page?
Title: Re: Fuel pump
Post by: alludc on Aug 20, 2014, 12:36:00 pm
he wasnt interested in discussing details (like the FB post said they were). just wanted my VIN and off he went.
Title: Re: Fuel pump
Post by: RonKy on Aug 20, 2014, 03:04:06 pm
Pinocchio told me the same thing...NEVER had he even heard of such a problem and even said they had experts trolling the internet, looking for these types of problems.  I told him I could send him some comments from others who stated they had called about their failed pump but he would have none of that.   He asked for my VIN, and that was the end of the conversation.  I addressed my facebook pic and comment directly to him.
Title: Re: Fuel pump
Post by: Paladin on Aug 20, 2014, 03:50:57 pm
In CA, the fuel pump is part of the emissions package, which in CA is warranted for (5) five years.  This is why they don't want to hear about their fuel pumps failing. It would trigger a recall on the pumps.
Title: Re: Fuel pump
Post by: alludc on Aug 20, 2014, 04:06:11 pm
$420 here if you need one... http://www.dealercostparts.com/pages/oemparts#%2fYamaha%2fROADLINER_S_-_XV19SW_-_2007%2fFUEL_TANK_2%2fXV19SW_%282007_MOTORCYCLE%29%2fFUEL_TANK_2_%28XV19SW_-_2007%29
Title: Re: Fuel pump
Post by: Ares X on Aug 20, 2014, 04:23:06 pm
In CA, the fuel pump is part of the emissions package, which in CA is warranted for (5) five years.  This is why they don't want to hear about their fuel pumps failing. It would trigger a recall on the pumps.

Then we should do everything we can to get the word out.  Isn't the same fuel pump used on the Strats and Roadliners?  Are they having these issues?
Title: Re: Fuel pump
Post by: alludc on Aug 20, 2014, 04:38:37 pm
In CA, the fuel pump is part of the emissions package, which in CA is warranted for (5) five years.  This is why they don't want to hear about their fuel pumps failing. It would trigger a recall on the pumps.

Then we should do everything we can to get the word out.  Isn't the same fuel pump used on the Strats and Roadliners?  Are they having these issues?

yup, same pump.  from my research, I dont see it being brought up.  id assume a large majority of people with this issue just ran to dealer, and dealer replaced quietly under warranty, or charged em and never showed why
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 02:24:50 am
Not sure why y'all didn't read my second post in this thread. Go back and read it again. Can't seem to get my paste to work on my phone. But it's an alternative cheaper pump fix from Roadliner Stratoliner forum.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 21, 2014, 03:17:26 am
Since I now own a 2007 Roadliner I've been lurking on some other forums. If I can find it, someone has figured out a way to replace with a cheaper automotive pump. I'll dig around and try to provide a link.

Yall should check out some of the Roadliner/Stratoliner sites, lots of cool info that will work for our Raiders not discussed here.

Found it. http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&msg=27822.3 (http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&msg=27822.3)

This one? Oh what da you know for crips sake, you shoe horned a v8 into a Vega!  ;D j/k Always wanted to do that but never cash or time together. Had 2 wagons and that was a plan. Wonder if there are any around anymore. LS3 Vega would be tight. Anyway, thanks for the link and I hope it helps people with options.
Title: Re: Fuel pump
Post by: Paladin on Aug 21, 2014, 04:56:09 am
v8_vega,

This is what is posted on the other forum;

"Wow, pics would have been a good idea while we were doing the replacement.  I wasn't thinking about documenting the process at the time.  Fortunately, the steps aren't complicated.  The pump we chose came with a bag of extra parts, including crimp connectors for splicing the new connector onto the old wiring.  Trimming the plastic spacer is pretty obvious too.  Take a pair of diagonals and clip off the end of the tab on the spacer.  This lets it sit flat on the surface of the new pump."

There is no mention of the pump's brand, how much it cost, where to get it, or what's involved when adapting it to the Strat, Roadliner or Raider. Did you post a link to the wrong page?
Title: Re: Fuel pump
Post by: ladrox on Aug 21, 2014, 05:14:04 am
Mines replaced but I'm left wondering how confident I would feel taking off on a road trip with a "patched" pump.
Title: Re: Fuel pump
Post by: t84a on Aug 21, 2014, 07:00:17 am
Not sure why y'all didn't read my second post in this thread. Go back and read it again. Can't seem to get my paste to work on my phone. But it's an alternative cheaper pump fix from Roadliner Stratoliner forum.

I think the Liner guys are complaining about a failed pump. The problem with the Raider is not the pump but the plastic resevoir. Its odd that the Liner pumps are not failing. Maybe a heat issue.
Title: Re: Fuel pump
Post by: ladrox on Aug 21, 2014, 07:15:50 am
Wonder if there is a clearance problem in the secondary tank. That or a "bad" batch of plastic when they molded the resevoir. Idk, just thoughts....

Regardless, Yamaha needs to acknowledge problem.
Title: Re: Fuel pump
Post by: t84a on Aug 21, 2014, 07:21:43 am
Liners and Raiders share identical pumps. This is a tough one to figure out.
Title: Re: Fuel pump
Post by: Ares X on Aug 21, 2014, 09:47:53 am
Is it possible that it's positioned to where it's getting more heat at the failure spot on the Raider?
Title: Re: Fuel pump
Post by: alludc on Aug 21, 2014, 10:54:49 am
To be fair.... Yamaha corporate called me back yesterday after my 2nd, unhappy, message on FB.  I actually had a great conversation with someone (an actual manager) who asked questions and gave a shit...

While no promises were made, arrangements have been made for Yamaha to look at my pump this wkd.  I will gather as much information, pictures, etc as I can for all of you.

That being said, someone earlier mentioned that their fuel pumps were covered under California emissions for 5 years.  Thats true, but actually ALL Raiders are covered by that same warranty.  To be specific, its 5years and 30k Kilometers ( 18,641 miles ).  Yes, thats actually how its covered. 

I, at 14k miles and 4years8mos old fall in to this emissions based warranty. 

I realize I am one of the lowest mileage Raiders with this issue, at least on here.  But it would be good to get that info out.   I will update more after I bring the bike to Yamaha.
Title: Re: Fuel pump
Post by: t84a on Aug 21, 2014, 11:09:37 am
So yours was fixed under this warranty?

To be fair.... Yamaha corporate called me back yesterday after my 2nd, unhappy, message on FB.  I actually had a great conversation with someone (an actual manager) who asked questions and gave a shit...

While no promises were made, arrangements have been made for Yamaha to look at my pump this wkd.  I will gather as much information, pictures, etc as I can for all of you.

That being said, someone earlier mentioned that their fuel pumps were covered under California emissions for 5 years.  Thats true, but actually ALL Raiders are covered by that same warranty.  To be specific, its 5years and 30k Kilometers ( 18,641 miles ).  Yes, thats actually how its covered. 

I, at 14k miles and 4years8mos old fall in to this emissions based warranty. 

I realize I am one of the lowest mileage Raiders with this issue, at least on here.  But it would be good to get that info out.   I will update more after I bring the bike to Yamaha.

Title: Re: Fuel pump
Post by: Ares X on Aug 21, 2014, 11:15:24 am
So yours was fixed under this warranty?

To be fair.... Yamaha corporate called me back yesterday after my 2nd, unhappy, message on FB.  I actually had a great conversation with someone (an actual manager) who asked questions and gave a shit...

While no promises were made, arrangements have been made for Yamaha to look at my pump this wkd.  I will gather as much information, pictures, etc as I can for all of you.

That being said, someone earlier mentioned that their fuel pumps were covered under California emissions for 5 years.  Thats true, but actually ALL Raiders are covered by that same warranty.  To be specific, its 5years and 30k Kilometers ( 18,641 miles ).  Yes, thats actually how its covered. 

I, at 14k miles and 4years8mos old fall in to this emissions based warranty. 

I realize I am one of the lowest mileage Raiders with this issue, at least on here.  But it would be good to get that info out.   I will update more after I bring the bike to Yamaha.


Not yet.  He's having it checked this weekend.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 21, 2014, 12:36:16 pm
Is it possible that it's positioned to where it's getting more heat at the failure spot on the Raider?

The position and orientation is the same on both models. The only thing I can think of, and I don't have time right now to verify, is something after the pump is different. Maybe the injectors or the pressure regulators that are causing an excess of pressure inside the pump housing causing it to rupture.
Title: Re: Fuel pump
Post by: Phaedrus on Aug 21, 2014, 01:06:25 pm
Petey_08
I liked your solution (I assume it's still holding).
Given the fact you've actually handled the pump...do you think the plastic cylinder that's cracking could be wrapped in something or have tight plastic sleeve placed around it for additional reinforcement?
Title: Re: Fuel pump
Post by: Ares X on Aug 21, 2014, 01:09:28 pm
Petey_08
I liked your solution (I assume it's still holding).
Given the fact you've actually handled the pump...do you think the plastic cylinder that's cracking could be wrapped in something or have tight plastic sleeve placed around it for additional reinforcement?

I was wondering that same thing.  Maybe just wrap with a large hose clamp.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 21, 2014, 03:04:18 pm
Petey_08
I liked your solution (I assume it's still holding).
Given the fact you've actually handled the pump...do you think the plastic cylinder that's cracking could be wrapped in something or have tight plastic sleeve placed around it for additional reinforcement?

I was wondering that same thing.  Maybe just wrap with a large hose clamp.

The solution in the video has since failed, the patch didn't bond with the plastic so I was surprised that it lasted as long as it has. I have since plastic welded the area which is a more permanent solution. I was going for an easy solution that the average person could do which is why I chose to patch it the first time.
I also thought about wrapping it, but no, I don't think it could be wrapped. The problem is its shape, it is kind of shaped like this: C< semi-circular with a v notch in it. The location of the crack is generally right near an edge, where the C and the < meet. Honestly, I think plastic welding is the best option. If you can get enough material on there, you can create a joint that is stronger than the original, making it a permanent fix.
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 03:37:51 pm
http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&amp;msg=27822.1 (http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&amp;msg=27822.1)

Maybe this will help. Not sure why other link started on third message which was past the info I wanted to share. Sorry fellas, but managed to get a link on this time. Will try it myself and see if it works.
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 03:41:41 pm
Think I got it right this time. Will fix other link also.
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 03:48:31 pm

This one? Oh what da you know for crips sake, you shoe horned a v8 into a Vega!  ;D j/k Always wanted to do that but never cash or time together. Had 2 wagons and that was a plan. Wonder if there are any around anymore. LS3 Vega would be tight. Anyway, thanks for the link and I hope it helps people with options.

I did have myself a 72 GT Wagon, was the most fun I've ever had with a motorized anything. Told my wife last week that I would gladly trade both bikes for another one like it lol. One day I will hopefully own another... yes they are still out here, just harder to find.
Title: Re: Fuel pump
Post by: alludc on Aug 21, 2014, 03:53:18 pm
http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&amp;msg=27822.1 (http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&amp;msg=27822.1)

Maybe this will help. Not sure why other link started on third message which was past the info I wanted to share. Sorry fellas, but managed to get a link on this time. Will try it myself and see if it works.

your link probably only works for logged in members of that site... it directs everyone else to a home page
nope doesnt work after a member either
Title: Re: Fuel pump
Post by: Paladin on Aug 21, 2014, 04:20:52 pm
v8-vega,

How 'bout just copying and pasting the info on this site?
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 08:10:45 pm
Ok, I'll try that. I'll also try the link with laptop in the morning. Maybe a mobile link is why it's redirecting.
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 08:12:33 pm
If you're experiencing hard starting or stalling, especially when the bike is warm, then you might want to check your fuel pressure.  My son's liner was difficult to start at times.  It cranked fine but wouldn't always fire up.  He also had trouble at times keeping it running below a couple thousand RPMs.  We checked the fuel pressure, and it was at 46 psi.  The manual says around 56 psi is normal, and my liner measures 60 psi.  Of course Yamaha wants big bucks for the fuel pump assembly, but we stumbled onto this thread giving some alternate options for the pump (this forum is great!).  We went down to O'Reillys and settled on a pump for a 1990 Suzuki Swift.  This is just the pump and not the full Yamaha-specific housing that it sits in.  We paid about $150, but we found the same or similar pump online for less.  The Yamaha fuel pump assembly comes out of the lower tank from the top.  It takes some twisting and turning, but it comes out.  You remove the lower plastic piece from the housing, disconnect one connector, and slide the pump out of the housing from the bottom.  The new pump comes with a strainer that is the correct shape to fit in the lower tank.  The electrical connector is different, and you have to cut off the stock connector and splice in the one that comes with the pump.  You also have to trim the tab on the plastic spacer that fits on the outlet pipe.  We slapped it back together and measured 60 psi fuel pressure.  His bike starts and runs strong once again.

...and some pix from member 'Chappy':
Internal Fuel Tank and Pump Removal Pictures (are in reverse order)
And Internal Fuel Tank Removal Procedures
Title: Re: Fuel pump
Post by: ladrox on Aug 21, 2014, 08:19:08 pm
Well, Yami has been sending me messages on facebook. The last one was an sr#. So I will call tomorrow and see what happens.
Title: Re: Fuel pump
Post by: v8_vega on Aug 21, 2014, 08:21:07 pm
v8_vega,

This is what is posted on the other forum;

"Wow, pics would have been a good idea while we were doing the replacement.  I wasn't thinking about documenting the process at the time.  Fortunately, the steps aren't complicated.  The pump we chose came with a bag of extra parts, including crimp connectors for splicing the new connector onto the old wiring.  Trimming the plastic spacer is pretty obvious too.  Take a pair of diagonals and clip off the end of the tab on the spacer.  This lets it sit flat on the surface of the new pump."

There is no mention of the pump's brand, how much it cost, where to get it, or what's involved when adapting it to the Strat, Roadliner or Raider. Did you post a link to the wrong page?


This was post number 3 in that thread I've been trying to get right. If you had clicked the arrow back to first post, it was the start of the thread which for some dang reason I can't get right. But the link worked to get you to the 3rd message in that thread so not sure why it's not working now. All it did was change the last number from 3 to 1 when I clicked to start of post. So I then copied that link. Works for me, but it could be a mobile thing, because it shows I'm a guest as well.I'll work on it in the morning, at work now.
Title: Re: Fuel pump
Post by: t84a on Aug 21, 2014, 08:23:19 pm
This is not the same problem being discussed here.

If you're experiencing hard starting or stalling, especially when the bike is warm, then you might want to check your fuel pressure.  My son's liner was difficult to start at times.  It cranked fine but wouldn't always fire up.  He also had trouble at times keeping it running below a couple thousand RPMs.  We checked the fuel pressure, and it was at 46 psi.  The manual says around 56 psi is normal, and my liner measures 60 psi.  Of course Yamaha wants big bucks for the fuel pump assembly, but we stumbled onto this thread giving some alternate options for the pump (this forum is great!).  We went down to O'Reillys and settled on a pump for a 1990 Suzuki Swift.  This is just the pump and not the full Yamaha-specific housing that it sits in.  We paid about $150, but we found the same or similar pump online for less.  The Yamaha fuel pump assembly comes out of the lower tank from the top.  It takes some twisting and turning, but it comes out.  You remove the lower plastic piece from the housing, disconnect one connector, and slide the pump out of the housing from the bottom.  The new pump comes with a strainer that is the correct shape to fit in the lower tank.  The electrical connector is different, and you have to cut off the stock connector and splice in the one that comes with the pump.  You also have to trim the tab on the plastic spacer that fits on the outlet pipe.  We slapped it back together and measured 60 psi fuel pressure.  His bike starts and runs strong once again.

...and some pix from member 'Chappy':
Internal Fuel Tank and Pump Removal Pictures (are in reverse order)
And Internal Fuel Tank Removal Procedures
Title: Re: Fuel pump
Post by: v8_vega on Aug 22, 2014, 02:03:58 am
It is the exact problem this whole thread is about, the fuel pump. This, is an alternative if you have to replace yourself. One member has ordered one at way above the price this alternative cost and another mentioned if the Roadliner Stratoliner group has had problems. Just trying to help put out more info. I've already went through this problem once, and now I also have a Roadliner so the possibility of going through it again has doubled for myself.
Title: Re: Fuel pump
Post by: v8_vega on Aug 22, 2014, 03:32:24 am
Looking back at the pictures, I don't see how the crack is in a pressure zone. Most pump assemblies are built with the suction side of the pump in a baffled area. The pressure side of pump is normally directly connected to the outlet on top of tank. I haven't actually seen the Raider or Liner assembly, but I can't imagine them to have something totally different then any other pump assembly I've replaced or repaired. The only reason I didn't do mine was because of warranty. But I had already diagnosed and confirmed my suspicions before even taking it to the dealership.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 22, 2014, 05:02:50 am
Looking back at the pictures, I don't see how the crack is in a pressure zone. Most pump assemblies are built with the suction side of the pump in a baffled area. The pressure side of pump is normally directly connected to the outlet on top of tank. I haven't actually seen the Raider or Liner assembly, but I can't imagine them to have something totally different then any other pump assembly I've replaced or repaired. The only reason I didn't do mine was because of warranty. But I had already diagnosed and confirmed my suspicions before even taking it to the dealership.

That's my take as well. With the crack going to the inside it just looked like it was trying to collapse the black portion. I even was looking at fluid hammer causing the problem and was looking for a video to explain it. If this black piece is truly in the pressure area then the vacuum created by fluid hammer could be the root cause. I'll see if I can find a decent video to explain it. I don't see a fuel pump having enough pressure to create a pulsating wave where it could generate high enough vacuum to cause this kind of crack. I'm not explaining this very well. I'm hypothesizing that a gerotor pump could create a positive fuel pressure in one cycle and then a vacuum causing a flutter of the housing. What I'm thinking makes absolutely no sense. A pump should have constant pressure. Any engineering types out there? Has anyone put a damaged fuel pump into a bucket of water to verify that water squirts out of the crack as it should do if this is in the pressurized chamber? Conversely, if this is part of the suction feed you should have a solid water stream while the pump is submersed but once the crack is exposed then you'll have reduced flow and possibly bubbles. If this is on the suction side, a patch or plastic weld should fix it...for awhile.

The reason I'm thinking fluid hammer is from a report I did on Aloha Airlines Flight 243 from back in 1988. I'll post an article for those bored enough to read it. Basically the fuselage started coming apart and a stewardess was near the initial crack. It sucked her through the crack and opened it but her body plugged the hole. Instant air pressure spiked and blew the rest of the fuselage apart.

http://the.honoluluadvertiser.com/2001/Jan/18/118localnews1.html

Fluid hammer
https://www.youtube.com/watch?v=X9UbzcanuDk

This is all mumbo jumbo and the bottom line is the pumps are failing and Yamaha needs to figure this out. A different pump as V8_Vega is steering us too could be a viable solution. I need sleep, my brain has failed. Out
Title: Re: Fuel pump
Post by: t84a on Aug 22, 2014, 07:23:23 am
This thread is about the plastic reservoir. There is nothing wrong with the actual pump. The Liner thread is about replacing the pump (only) with an automotive one and reusing the plastic reservoir-the part that is the problem with the Raider.

It is the exact problem this whole thread is about, the fuel pump. This, is an alternative if you have to replace yourself. One member has ordered one at way above the price this alternative cost and another mentioned if the Roadliner Stratoliner group has had problems. Just trying to help put out more info. I've already went through this problem once, and now I also have a Roadliner so the possibility of going through it again has doubled for myself.
Title: Re: Fuel pump
Post by: ladrox on Aug 22, 2014, 07:39:49 am
Looking back at the pictures, I don't see how the crack is in a pressure zone. Most pump assemblies are built with the suction side of the pump in a baffled area. The pressure side of pump is normally directly connected to the outlet on top of tank. I haven't actually seen the Raider or Liner assembly, but I can't imagine them to have something totally different then any other pump assembly I've replaced or repaired. The only reason I didn't do mine was because of warranty. But I had already diagnosed and confirmed my suspicions before even taking it to the dealership.

That's my take as well. With the crack going to the inside it just looked like it was trying to collapse the black portion. I even was looking at fluid hammer causing the problem and was looking for a video to explain it. If this black piece is truly in the pressure area then the vacuum created by fluid hammer could be the root cause. I'll see if I can find a decent video to explain it. I don't see a fuel pump having enough pressure to create a pulsating wave where it could generate high enough vacuum to cause this kind of crack. I'm not explaining this very well. I'm hypothesizing that a gerotor pump could create a positive fuel pressure in one cycle and then a vacuum causing a flutter of the housing. What I'm thinking makes absolutely no sense. A pump should have constant pressure. Any engineering types out there? Has anyone put a damaged fuel pump into a bucket of water to verify that water squirts out of the crack as it should do if this is in the pressurized chamber? Conversely, if this is part of the suction feed you should have a solid water stream while the pump is submersed but once the crack is exposed then you'll have reduced flow and possibly bubbles. If this is on the suction side, a patch or plastic weld should fix it...for awhile.

The reason I'm thinking fluid hammer is from a report I did on Aloha Airlines Flight 243 from back in 1988. I'll post an article for those bored enough to read it. Basically the fuselage started coming apart and a stewardess was near the initial crack. It sucked her through the crack and opened it but her body plugged the hole. Instant air pressure spiked and blew the rest of the fuselage apart.

http://the.honoluluadvertiser.com/2001/Jan/18/118localnews1.html

Fluid hammer
https://www.youtube.com/watch?v=X9UbzcanuDk

This is all mumbo jumbo and the bottom line is the pumps are failing and Yamaha needs to figure this out. A different pump as V8_Vega is steering us too could be a viable solution. I need sleep, my brain has failed. Out

There is a video on youtube showing the pump squirting fuel out of the crack...with some authority too!
Title: Re: Fuel pump
Post by: Petey_08 on Aug 22, 2014, 08:25:30 am
There is a video on youtube that just shows the crack squirting fuel and the video I posted also shows this:

http://youtu.be/jKaqwBeV1Vw
*UPDATE*
The patch eventually failed, so don't try it at home. Best bet is to plastic weld.

The plastic housing that we are referring to is definitely in the pressure zone, it is the swirl pot. Most fuel pump applications I have seen have something similar. It is important on motorcycles, as you corner and the fuel sloshes around in the tank, the swirl pot ensures that you still get fuel to the engine when the pump picks up air.
Title: Re: Fuel pump
Post by: alludc on Aug 22, 2014, 09:34:28 am
for the uninstall watch the link above.

To see just the crack and the spray out of the crack start here at 9:30 mark of the vid  http://youtu.be/jKaqwBeV1Vw?t=9m30s
Title: Re: Fuel pump
Post by: Ares X on Aug 22, 2014, 10:04:45 am
This thread is about the fuel pump failing (look at page one) and all info on it is relevant.

This thread is about the plastic reservoir. There is nothing wrong with the actual pump. The Liner thread is about replacing the pump (only) with an automotive one and reusing the plastic reservoir-the part that is the problem with the Raider.

It is the exact problem this whole thread is about, the fuel pump. This, is an alternative if you have to replace yourself. One member has ordered one at way above the price this alternative cost and another mentioned if the Roadliner Stratoliner group has had problems. Just trying to help put out more info. I've already went through this problem once, and now I also have a Roadliner so the possibility of going through it again has doubled for myself.
Title: Re: Fuel pump
Post by: Ares X on Aug 22, 2014, 10:06:41 am
For those that have a dealer check their system for failure, if they say it has pressure and nothing is wrong, have them let it set for a moment when turned off and test it again.  Mine would lose pressure after sitting for a moment.  The service rep argued with me over and over that it was holding pressure and then a short while later called back and let me know that it lost pressure after it was turned off. So something to keep in mind.
Title: Re: Fuel pump
Post by: t84a on Aug 22, 2014, 10:15:48 am
So why are all the posts about cracks?

This thread is about the fuel pump failing (look at page one) and all info on it is relevant.

This thread is about the plastic reservoir. There is nothing wrong with the actual pump. The Liner thread is about replacing the pump (only) with an automotive one and reusing the plastic reservoir-the part that is the problem with the Raider.

It is the exact problem this whole thread is about, the fuel pump. This, is an alternative if you have to replace yourself. One member has ordered one at way above the price this alternative cost and another mentioned if the Roadliner Stratoliner group has had problems. Just trying to help put out more info. I've already went through this problem once, and now I also have a Roadliner so the possibility of going through it again has doubled for myself.
Title: Re: Fuel pump
Post by: Ares X on Aug 22, 2014, 10:20:40 am
If you start on page 1 of this thread, they're not.  A crack is what most people are finding is the issue. I'm not sure what my issues were since I never saw the fuel pumps and had no idea what to look for at the time.   This thread is stickied and is meant to give all kinds of information regarding the fuel pump issues.

So why are all the posts about cracks?

This thread is about the fuel pump failing (look at page one) and all info on it is relevant.

This thread is about the plastic reservoir. There is nothing wrong with the actual pump. The Liner thread is about replacing the pump (only) with an automotive one and reusing the plastic reservoir-the part that is the problem with the Raider.

It is the exact problem this whole thread is about, the fuel pump. This, is an alternative if you have to replace yourself. One member has ordered one at way above the price this alternative cost and another mentioned if the Roadliner Stratoliner group has had problems. Just trying to help put out more info. I've already went through this problem once, and now I also have a Roadliner so the possibility of going through it again has doubled for myself.
Title: Re: Fuel pump
Post by: ladrox on Aug 22, 2014, 11:23:15 am
I just got off the phone with Yamaha. They took all my information and logged a "complaint". Of course I have to many miles and to much out of warranty. I didnt expect nothing and asked for nothing and told him so but....its become an issue on the Raider and I told them it should be documented as such. My .02.....

One thing tho...this guy was talking 90 miles a minute and reading from an obvious que card, that was irritating.
Title: Re: Fuel pump
Post by: alludc on Aug 22, 2014, 11:25:43 am
I just got off the phone with Yamaha. They took all my information and logged a "complaint". Of course I have to many miles and to much out of warranty. I didnt expect nothing and asked for nothing and told him so but....its become an issue on the Raider and I told them it should be documented as such. My .02.....

the more the better. thanks!
Title: Re: Fuel pump
Post by: ladrox on Aug 22, 2014, 11:26:39 am
 :thumbs:
Title: Re: Fuel pump
Post by: CHROMINATOR on Aug 22, 2014, 11:30:40 am
I just got off the phone with Yamaha. They took all my information and logged a "complaint". Of course I have to many miles and to much out of warranty. I didnt expect nothing and asked for nothing and told him so but....its become an issue on the Raider and I told them it should be documented as such. My .02.....

One thing tho...this guy was talking 90 miles a minute and reading from an obvious que card, that was irritating.

What?  You think they are going to memorize all that crap they think we want to hear?...  :o  :poke:

Seriously even if reading off a cue card it's good that he filed a complaint.  Each one that is documented like that is one step closer to a possible recall and fix.
Title: Re: Fuel pump
Post by: Ares X on Aug 22, 2014, 11:36:17 am
I just got off the phone with Yamaha. They took all my information and logged a "complaint". Of course I have to many miles and to much out of warranty. I didnt expect nothing and asked for nothing and told him so but....its become an issue on the Raider and I told them it should be documented as such. My .02.....

One thing tho...this guy was talking 90 miles a minute and reading from an obvious que card, that was irritating.

Mine was covered by Yamaha at 70,000 miles. Granted this was my second one, but I never imagined them to cover it.  I just called to get an idea if this was something I was going to be dealing with every year and a half.
Title: Re: Fuel pump
Post by: alludc on Aug 23, 2014, 12:09:19 pm
Bike is dropped off for inspection...
Title: Re: Fuel pump
Post by: alludc on Aug 23, 2014, 05:04:19 pm
Today was a good day.  Was able to ride my Raider to Apache Motorcycles in Scottsdale and there was my new pump (overnighted via yamaha corporate).  The pump was taken out, inspected...and yes of course...same crack/same place.  New pump put in and my beast is back.

Huge thanks to Brian @ Yamaha Corporate for calling me back, listening (and believing) my story..and getting this done so quickly.  Im very impressed. 

In case it gets overlooked above, please remember that your bike has an emissions warranty which is 30k kilometers (18,600 miles) and 5 years.  The fuel pump falls in to this warranty.

Brian/Yamaha said they would do what they can to track this problem.  If you had this problem and paid out of pocket (during warranty), you should try to see if Yamaha will help you.  If this happened to you not too fair past the 18000 mile warranty...you should try as well.  for those with much more mileage or age before it happened to you...at least report it.

Please share this info on the other 1900 boards for Roadies and Strats if you frequent those sites.

(http://img.photobucket.com/albums/v441/sskillz/bike/1_1_zps97611d3b.jpg) (http://smg.photobucket.com/user/sskillz/media/bike/1_1_zps97611d3b.jpg.html)

Title: Re: Fuel pump
Post by: Paladin on Aug 23, 2014, 07:05:17 pm
If you can determine the the O.D. radius of the plastic area that cracks, you might be able to find some thin walled tubing, where the tubing's I.D. matches the plastic's O.D. Then split the tubing length wise and bond it over the plastic area. There's a bonding material called "marine-tex" that is designed to repair engine water jackets, and is impervious to diesel fuel. It also states that it bonds to many different plastics. Their website is: www.marinetex.com Although I haven't used this product for this particular application, I have used it in the past for many other applications and can vouch for its repair and bonding abilities.
Title: Re: Fuel pump
Post by: RuneRaider on Aug 23, 2014, 07:14:10 pm
Worth a try and I'm sure surface prep is included in the directions. Grease and wax remover, scuff and reclean. It's been sitting in gas so doubt there'd be any grease or other contaminents. Thanks for the link.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 23, 2014, 07:25:55 pm
If you can determine the the O.D. radius of the plastic area that cracks, you might be able to find some thin walled tubing, where the tubing's I.D. matches the plastic's O.D. Then split the tubing length wise and bond it over the plastic area. There's a bonding material called "marine-tex" that is designed to repair engine water jackets, and is impervious to diesel fuel. It also states that it bonds to many different plastics. Their website is: www.marinetex.com Although I haven't used this product for this particular application, I have used it in the past for many other applications and can vouch for its repair and bonding abilities.

From their website:
"What does Marine-Tex NOT adhere to?
Plastics like polyethylene and polypropylene, and also any unclean, oily, greasy, or otherwise contaminated surface."

I'm pretty sure that the housing is one of the poly plastics, or one of the plastics that nothing will bond to. I'm not 100%, but the burn tests I did strongly suggest that it is a poly plastic. Best bet is just plastic welding the crack.
Title: Re: Fuel pump
Post by: Paladin on Aug 23, 2014, 09:42:06 pm
If you can determine the the O.D. radius of the plastic area that cracks, you might be able to find some thin walled tubing, where the tubing's I.D. matches the plastic's O.D. Then split the tubing length wise and bond it over the plastic area. There's a bonding material called "marine-tex" that is designed to repair engine water jackets, and is impervious to diesel fuel. It also states that it bonds to many different plastics. Their website is: www.marinetex.com Although I haven't used this product for this particular application, I have used it in the past for many other applications and can vouch for its repair and bonding abilities.

From their website:
"What does Marine-Tex NOT adhere to?
Plastics like polyethylene and polypropylene, and also any unclean, oily, greasy, or otherwise contaminated surface."

I'm pretty sure that the housing is one of the poly plastics, or one of the plastics that nothing will bond to. I'm not 100%, but the burn tests I did strongly suggest that it is a poly plastic. Best bet is just plastic welding the crack.
Well, I guess the only true test would be to mix up some marine-tex and test its bonding ability on the plastic area of a bad pump. 
Title: Re: Fuel pump
Post by: Ares X on Aug 25, 2014, 10:16:09 am
alludc- Glad that worked out for you.  Both of my pumps were well beyond the 18,000 mile warranty, so I definitely lucked out getting Yamaha to cover my second pump at 70,000 miles.

Hopefully this will get Yamaha into looking at this issue and coming up with a fix.
Title: Re: Fuel pump
Post by: alludc on Aug 25, 2014, 11:00:30 am
alludc- Glad that worked out for you.  Both of my pumps were well beyond the 18,000 mile warranty, so I definitely lucked out getting Yamaha to cover my second pump at 70,000 miles.

Hopefully this will get Yamaha into looking at this issue and coming up with a fix.

I surely hope so.  Once I reached the right guy...it was a great experience with Yamaha.  Its part persistence, thats for sure.  When he said they would look more carefully at it, I believed him.  He also mentioned even if I was over mileage, and it was indeed cracked...he would do his best to take care of it.

As far as the dealer goes, he admitted that he has had a number of bikes this year coming in with similar symptoms that would either not duplicate in their presence, nor could they find a cause.  Sound like they went down the line and did what most of us looked at 1st. plugs, filters, wires, coils, etc.  Had anyone checked Fuel pressure, they may have started inching their way towards the pump.  I sure would be curious to know how many FP claims have been made though.

Can we add any new info to the 1st post on this thread so all the other 15 pages dont get missed?  on another site I frequent, they have a 'user wiki' that goes directly below the 1st post so that updated info can be added for quick viewing.
Title: Re: Fuel pump
Post by: Ares X on Aug 25, 2014, 11:19:02 am
What is it you're wanting to add to the first post?
Title: Re: Fuel pump
Post by: alludc on Aug 25, 2014, 11:28:46 am
What is it you're wanting to add to the first post?

id add info about the location of cracks, state that the emissions warranty covers it if in that range, and to check Fuel pressure as the 1st bit troubleshooting if experiencing the symptoms on Dreadlys 1st post.
Title: Re: Fuel pump
Post by: Roadstrat on Aug 28, 2014, 05:56:56 pm
curious to know what kind of starting issues did anyone have regarding fuel pump.
Title: Re: Fuel pump
Post by: alludc on Aug 28, 2014, 05:59:33 pm
curious to know what kind of starting issues did anyone have regarding fuel pump.

For me, the starting issues were probably my 1st clue.  I managed to actually burn through a battery in 6 mos.  I replaced it, and my hard starts didnt get any easier.  still would take either some time or throttle or both.  Usually both.  Id say the starter would crank at least 5 solid times before it would start and this was normal. 

Now that Ive had my FP replacement, it fires on the 1st stroke everytime.  its a beautiful thing
Title: Re: Fuel pump
Post by: Ares X on Aug 28, 2014, 07:31:26 pm
curious to know what kind of starting issues did anyone have regarding fuel pump.

Both times my fuel pumps went out my batteries needed to be replaced.   I'm used to a single fire start as well.
Title: Re: Fuel pump
Post by: Roadstrat on Aug 28, 2014, 09:00:26 pm
my problem is if the bike sits overnight it won't fire right away.
I usually hold the start button 2 or 3 secs and release if it does'nt
start. Then i hit the start again and it fires right up.
I can't see this being a pump issue but i could be wrong.
Title: Re: Fuel pump
Post by: alludc on Aug 28, 2014, 09:12:42 pm
my problem is if the bike sits overnight it won't fire right away.
I usually hold the start button 2 or 3 secs and release if it does'nt
start. Then i hit the start again and it fires right up.
I can't see this being a pump issue but i could be wrong.

id bet that even after it sat for an hour or two it would show the same.  FP leaks down too much.  Fairly certain AresX described that scenario in this thread, somewhere.
Title: Re: Fuel pump
Post by: the urban legend on Aug 28, 2014, 09:18:59 pm
my problem is if the bike sits overnight it won't fire right away.
I usually hold the start button 2 or 3 secs and release if it does'nt
start. Then i hit the start again and it fires right up.
I can't see this being a pump issue but i could be wrong.

Could be.

The first time you crank,the pump is building up pressure.Then it's readily available on the second attempt so it starts right up.
I've never paid attention if the pump runs as soon as the ignition is turned on.With all the EXUP servo and IAC noise I can't hear the if the pump is going or not.I'll have to remove the seat and listen tomorrow morning.

My point is>>>If it does run as soon as you turn the key,you could try cycling the key on/off 3-4 times to prime the pressure before hitting the start button.If it starts right up that way,but doesn't if you just turn the key once and hit start,then you most likely have a fuel pressure leak.And since the pump housing seems to be the weak link,well........
Title: Re: Fuel pump
Post by: Petey_08 on Aug 28, 2014, 09:38:08 pm
my problem is if the bike sits overnight it won't fire right away.
I usually hold the start button 2 or 3 secs and release if it does'nt
start. Then i hit the start again and it fires right up.
I can't see this being a pump issue but i could be wrong.

This is the main problem my bike had with a cracked pump, it lost pressure as it sat. It would idle rough occasionally when it was warm, but the way you described starting your bike is exactly how I had to start mine.
Title: Re: Fuel pump
Post by: Roadstrat on Aug 28, 2014, 10:25:15 pm
i don't have any of the other problems like stalling or hesitating etc and it will fire up after sitting
for 4 or 5 hrs.
If the pump is building up pressure on the first crank then it should fire eventually
if i hold the start button long enough(never held it longer than 5 sec)
But it fires on the second try..thats what confuses me.
Title: Re: Fuel pump
Post by: Ares X on Aug 29, 2014, 09:38:01 am
If I remember correctly, and granted it's been a couple of years, when I had fuel pump issues, you could hear it trying to start, but it wouldn't always start.  Also, when it did start, it sounded rough at first. My wife used to say it sounded like a Harley in the garage. It just sounded like it wanted to die.  New problems crept up as time went on. Running poorly in idle. Eventually stalling a few times. On my last one, the last day I was riding before it was fixed, I could feel it cutting out at high speed and then kicking back in.  It ran worst in the afternoons. Probably because the fuel was lower and the temps were hotter.
Title: Re: Fuel pump
Post by: Roadstrat on Aug 29, 2014, 12:23:53 pm
when i try, it sounds like its just cranking and not trying to fire.
And no issues like you described.
thanx
I'm goin to try a few different scenarios when starting and see if anything new arises.
Title: Re: Fuel pump
Post by: Petey_08 on Aug 29, 2014, 02:28:24 pm
i don't have any of the other problems like stalling or hesitating etc and it will fire up after sitting
for 4 or 5 hrs.
If the pump is building up pressure on the first crank then it should fire eventually
if i hold the start button long enough(never held it longer than 5 sec)
But it fires on the second try..thats what confuses me.

I bought my bike with a bad fuel pump, so I can't tell you how the problems all arrived, but this is exactly how mine was. It didn't matter how long you held the start button the first time (held it for about 15 seconds one time with nothing) it would never start. Wait a few seconds, fired right up. It really only took a few turns the first time, let it sit, fired up. It did get worse, in the video I posted it didn't want to start at all, which was unusual. The other problems were intermittent, other than backfiring on decel. You may have the start of a crack, and over time it may just get worse. Then again, you may have a completely different problem.
Title: Re: Fuel pump
Post by: Roadstrat on Aug 29, 2014, 03:14:22 pm
this morning i went out hit the start button on and off quickly so it only
cranked for half a sec. Hit it again and fired right up.
Now this problem has been goin on 2 yrs now. The odd time it would
fire up on first try. I would think it would have gotten a lot worse over time
and have more issues.
I'm thinking back and remembering something about the de-compression solenoid
someone mentioned as a cause!!
Title: Re: Fuel pump
Post by: Ares X on Aug 29, 2014, 03:29:58 pm
this morning i went out hit the start button on and off quickly so it only
cranked for half a sec. Hit it again and fired right up.
Now this problem has been goin on 2 yrs now. The odd time it would
fire up on first try. I would think it would have gotten a lot worse over time
and have more issues.
I'm thinking back and remembering something about the de-compression solenoid
someone mentioned as a cause!!

I agree. The fuel pump issue wouldn't wait for two years.
Title: Re: Fuel pump
Post by: alludc on Aug 29, 2014, 03:49:33 pm
this morning i went out hit the start button on and off quickly so it only
cranked for half a sec. Hit it again and fired right up.
Now this problem has been goin on 2 yrs now. The odd time it would
fire up on first try. I would think it would have gotten a lot worse over time
and have more issues.
I'm thinking back and remembering something about the de-compression solenoid
someone mentioned as a cause!!

I agree. The fuel pump issue wouldn't wait for two years.

I know guys who only ride 1000 miles a year, so it is possible for some folk.
Title: Re: Fuel pump
Post by: Ares X on Aug 29, 2014, 03:58:55 pm
this morning i went out hit the start button on and off quickly so it only
cranked for half a sec. Hit it again and fired right up.
Now this problem has been goin on 2 yrs now. The odd time it would
fire up on first try. I would think it would have gotten a lot worse over time
and have more issues.
I'm thinking back and remembering something about the de-compression solenoid
someone mentioned as a cause!!

I agree. The fuel pump issue wouldn't wait for two years.

I know guys who only ride 1000 miles a year, so it is possible for some folk.

FREAKS!
Title: Re: Fuel pump
Post by: Roadstrat on Aug 29, 2014, 04:10:51 pm
this morning i went out hit the start button on and off quickly so it only
cranked for half a sec. Hit it again and fired right up.
Now this problem has been goin on 2 yrs now. The odd time it would
fire up on first try. I would think it would have gotten a lot worse over time
and have more issues.
I'm thinking back and remembering something about the de-compression solenoid
someone mentioned as a cause!!


I agree. The fuel pump issue wouldn't wait for two years.

I know guys who only ride 1000 miles a year, so it is possible for some folk.
You could be right. Because of medical problems(going blind)i only managed
3000mi in the last two summers. Freaky.!! :lolsign:
Title: Re: Fuel pump
Post by: alludc on Aug 29, 2014, 04:19:43 pm
From the 1st symptom (in hindsight), until undriveable...I had logged around 1800 miles.
Title: Re: Fuel pump
Post by: Roadstrat on Aug 29, 2014, 04:26:15 pm
i wonder if the emissions warranty applies to Canadian bikes. Gonna give the dealer a call
Title: Re: Fuel pump
Post by: alludc on Aug 29, 2014, 04:51:50 pm
i wonder if the emissions warranty applies to Canadian bikes. Gonna give the dealer a call

it does. 30km/5yr
Title: Re: Fuel pump
Post by: tice on Aug 29, 2014, 07:14:01 pm
Mine was a long crank with the occasional power loss while riding.
Title: Re: Fuel pump
Post by: Roadstrat on Sep 02, 2014, 03:06:45 pm
after thinkin' about this starting problem and fuel pump i decided to check the battery.
I put the battery tender on it overnight for the last 4 evenings and it started first time
each morning. So the battery is a little weak(5yrs old). Will have to look at getting a new one
though i'm not sayin i don't have a fuel pump problem yet...i'm just sayin !!
Title: Re: Fuel pump
Post by: ladrox on Sep 03, 2014, 06:43:31 am
You know, we all define things a little differently. When mine was bad I defined it as "cuts out when hot". But, I said from the day I bought it..."this bike feels like its starving for fuel". Pressure test will take all the guess work out of it. On a fuel injected bike 5 lbs might as well be 20...imo.
Title: Re: Fuel pump
Post by: mrdrak on Sep 18, 2014, 03:20:13 pm
The housing on the fuel pumps are cracking causing it to lose pressure. Mine would cut in and out at low rpm and stall at red lights when slowing down. Also hard to start. Didn't have a problem till 40000 miles.
Title: Re: Fuel pump
Post by: Deyv on Sep 21, 2015, 08:23:48 pm
What kind of mileage are we talking when symptoms start?

I believe:
Ares - 35k
Woodog - 31k
Wolfraider - 87k
Kewlraider - don't recall
v8_vega - don't recall
seventhLetter - don't recall
wileecoyote - Roadstar - 26k
Deyv - 65K

I'm currently at 25k ... nothing has failed yet but ...................

Alrighty, had most of the symptoms so was getting ready to bite the bullet on buying a new pump, until I found the post by Petey_08 and took it apart (like he shows in the video).  Found a crack, right where they all have been in the pictures.  Used a soldering iron to heat the area and melt the crack area back together.  Then used small peices of wire in a zig-zag formation and sunk it into the plastic, cross ways across the stress line.  The theory of it it to provide additional strength,  (saw it sone on several YouTube videos.  Then used part of the bracket structure for additional material to thicken the area of the patch.  Pictures are a little blurry, but you should get hte basic idea.  Was pleased with how little crud was in the bottom of the tank.  Put it all back together and the bike now starts right up with no hesitation.  Total time of the repair was 2 hours from set up to clean up...  Have to see how long it lasts.. but right now.. pretty happy with it...
Title: Re: Fuel pump
Post by: t84a on Sep 21, 2015, 08:26:51 pm
Nice. I'd be worried the wire would fall off into the tank. Nice work.
Title: Re: Fuel pump
Post by: Deyv on Sep 21, 2015, 08:35:43 pm
Nice. I'd be worried the wire would fall off into the tank. Nice work.

The pictures just weren't good enough to show, but the wire is completely covered by the plactic.  No wire showing at all, and since I used the same material, there shouldn't be any problem with material incompatibiltiy.

And thanks....:)
Title: Re: Fuel pump
Post by: wallasan10 on Sep 28, 2015, 10:25:51 am
I'm very interested in how this type of repair holds up.
Title: Re: Fuel pump
Post by: Luke on Sep 28, 2015, 12:08:36 pm
From the service manual, Am I correct when reading the Output Pressure from the fuel pump should be between 63.9 - 92.4 PSI?

This is on Sheet 2-9 in my book. 

When I have some time I may ck this out.
Title: Re: Fuel pump
Post by: the urban legend on Sep 28, 2015, 05:59:48 pm
From the service manual, Am I correct when reading the Output Pressure from the fuel pump should be between 63.9 - 92.4 PSI?

This is on Sheet 2-9 in my book. 

When I have some time I may ck this out.

That's the pressure that the pump should be able to generate.Basically you plug the pump outlet with the gauge and let her rip,and see how high it can go.
The operational pressure is 55.7 psi on page 6-16 of the service manual.
Title: Re: Fuel pump
Post by: Luke on Sep 29, 2015, 07:10:27 am
From the service manual, Am I correct when reading the Output Pressure from the fuel pump should be between 63.9 - 92.4 PSI?

This is on Sheet 2-9 in my book. 

When I have some time I may ck this out.

That's the pressure that the pump should be able to generate.Basically you plug the pump outlet with the gauge and let her rip,and see how high it can go.
The operational pressure is 55.7 psi on page 6-16 of the service manual.
From reading that section you will be checking that the fuel pressure regulator is working properly.  That would work as will.  So the pressure must be greater before the fuel gets to regulator as stated on the specification sheet 2-9.  Looks like it would be easier to ck the fuel pressure coming out of the pump rather than the regulator.
Title: Re: Cracked Fuel pump housing
Post by: zman on Sep 29, 2015, 01:50:12 pm
My fuel pump housing cracked apparently just like many others, looks like a very common problem, my 09 Raider has only 9k miles on it.
Can someone provide me a number for Yamaha as from what I am reading this could be covered under the emissions warranty

I tried to plastic weld the crack in the pump housing, after reinstalling it the bike fired right up and I thought I had repaired the crack.
No such luck apparently it didn't hold which was my fear but it was worth trying, bike still runs rough , extreme hesitation and back firing just as before.
Ordered the new pump today from Cheap Cycle parts for a mere $480 part #1D7-13907, unfortunately you are unable to just buy the plastic housing because there is nothing wrong with the pump itself. Now will this same problem occur in a couple of years????

I did contact Yamaha direct @ 800-962-7926, I of course asked if there was possibly a recall that I maybe somehow missed, they said no on the recall, I then asked if they would cover this as it appears as a product/manufacture defect . From what I have read this is frequently occurring to others.
They/Yamaha said I would have to take the bike into the dealership and then..... after 100 plus dollars per hr. for something I can do myself  they would possibly let me know what percentage of the repair total they if anything would be cover.
At this point I gave up and will replace it myself and eat the $$$$$
Update!!!!!!!!!!!!! see last picture I was able to solder it using a piece of extra housing and it's holding 
Title: Re: Fuel pump
Post by: Deyv on Sep 29, 2015, 02:00:18 pm
If you do get it replaced, under warranty, see if they'll let you keep the old one.  I'd like to have one to practice/experiment on.  Let me know.  Thanks.
Title: Re: Fuel pump
Post by: the urban legend on Sep 29, 2015, 07:59:33 pm
From the service manual, Am I correct when reading the Output Pressure from the fuel pump should be between 63.9 - 92.4 PSI?

This is on Sheet 2-9 in my book. 

When I have some time I may ck this out.

That's the pressure that the pump should be able to generate.Basically you plug the pump outlet with the gauge and let her rip,and see how high it can go.
The operational pressure is 55.7 psi on page 6-16 of the service manual.
From reading that section you will be checking that the fuel pressure regulator is working properly.  That would work as will.  So the pressure must be greater before the fuel gets to regulator as stated on the specification sheet 2-9.  Looks like it would be easier to ck the fuel pressure coming out of the pump rather than the regulator.

The pressure between the pump and regulator should be 55.7psi.Anything after the regulator (return line) should be almost zero psi.Any pressure reading there would indicate a pinched or clogged return line.
To read maximum pressure (63.9-92.4psi),you would have to cap the return line.With all these pump housings cracking,I wouldn't recommend it.
Title: Re: Fuel pump
Post by: bellabear on Oct 29, 2015, 09:03:49 pm
So we have the same problem mechanic shop said there was a crack in the fuel pump essembly which I call a housing (cover of the fuel pump) that sits in the reserve tank under the seat.  Watched a u-tube video where a person bought a kit at autozone ($17.00) to fix it, but he didn't show the product used on the item once it sealed the crack but said the directions were self explanatory.


Is this the same fix the rest of you did?
Title: Re: Fuel pump
Post by: tice on Oct 29, 2015, 09:07:51 pm
So we have the same problem mechanic shop their was a crack in the housing (cover of the fuel pump) that sits in the reserve tank under the seat.  Watched a u-tube video where a person bought a kit at autozone ($17.00) to fix it, but he didn't show the product used on the item once it sealed the crack but said the directions were self explanatory.

Is this the same fix the rest of you did?

I think his fix didnt last very long.
Title: Re: Fuel pump
Post by: Raiderguy on Oct 29, 2015, 10:19:53 pm
Mine is at the shop now for a new fuel pump, wow not a cheap part at all!
Title: Re: Fuel pump
Post by: tice on Oct 29, 2015, 10:24:37 pm
I did mine last summer and it still cost me over $550.00!!!!! Im gonna keep the YES warranty going on the Strat for when it goes bad.
Title: Re: Fuel pump
Post by: t84a on Oct 30, 2015, 08:38:02 am
Make sure you push the dealer on the 5 year emmissions warranty. The fuel pump is part of that.
Title: Re: Fuel pump
Post by: zman on Oct 30, 2015, 11:23:15 am
I plastic welded it by using a piece of extra housing and melted it with a solder iron to fill in the crack.
Mine is holding for now anyway- one month ago still working.
You must use the same material i.e. extra piece of the housing to weld it with the soldering iron or it wont adhere.
I did also go ahead and buy a new pump as a backup , not cheap $ 480 from Cheap cycle parts, may send it back as my repair is holding? for now. Total cost to plastic weld it was a $4 soldering iron I had to buy from Harbor freight.
Wished I would have just welded it before I ordered the new pump/housing and then tested it, bad timing on my part.- 8 days for the new part to be delivered, while waiting for the new pump I read how others had welded it.
Title: Re: Fuel pump
Post by: CHROMINATOR on Oct 31, 2015, 08:35:31 am
zman, How long was the crack in yours?  That weld is from top to bottom...  :o
Title: Re: Fuel pump
Post by: motorious on Nov 01, 2015, 07:02:29 am
From  symptoms listed here,I recognize my motorcycle manners....I am afraid it is the fuel pump or fuel pressure regulator problems.
Title: Re: Fuel pump
Post by: zman on Nov 04, 2015, 01:55:16 pm
I plastic welded it by using a piece of extra housing and melted it with a solder iron to fill in the crack.
Mine is holding for now anyway- one month ago still working.
You must use the same material i.e. extra piece of the housing to weld it with the soldering iron or it wont adhere.
I did also go ahead and buy a new pump as a backup , not cheap $ 480 from Cheap cycle parts, may send it back as my repair is holding? for now. Total cost to plastic weld it was a $4 soldering iron I had to buy from Harbor freight.
Wished I would have just welded it before I ordered the new pump/housing and then tested it, bad timing on my part.- 8 days for the new part to be delivered, while waiting for the new pump I read how others had welded it.
Title: Re: Fuel pump
Post by: t84a on Nov 04, 2015, 02:51:29 pm
What are we looking at in that pic?
Title: Re: Fuel pump
Post by: zman on Nov 04, 2015, 05:27:09 pm
The extra piece of material you can cut and use as filler to weld into the crack.
Title: Re: Fuel pump
Post by: zman on Nov 05, 2015, 11:49:30 am
About a 2 inch crack
Title: Re: Fuel pump
Post by: t84a on Nov 05, 2015, 12:12:40 pm
The extra piece of material you can cut and use as filler to weld into the crack.

Perfect. Thanks

How about throwing up the info on the tool you used to weld it. A member a while ago sent me his cracked one. I would be willing to fix it and send it to someone whose pump took a dump. If it worked out, I would only ask that they send me back the cracked one. Rinse and repeat.
Title: Re: Fuel pump
Post by: zman on Nov 05, 2015, 01:30:04 pm
The tool was just a standard $4 soldering iron from Harbor Freight.
Title: Re: Fuel pump
Post by: Deyv on Nov 11, 2015, 11:37:05 am
Another possible repair option is... Bonic plastic repair kit

http://www.amazon.com/Bondic-Anything-Waterproof-Resistant-Plastic/dp/B00QU5M4MG

Email back from the manufacturer...
Thank you for reaching out to the Bondic team!

We appreciate your interest in our product and are happy to assist you.

Yes, you can use our product to repair a stress crack on the pressure casing on the fuel pump. Without a picture, I can not give you any specific instructions, however we have plenty of visual demonstrations on www.youtube.com if you feel that may help assist you.

The only thing we would stress is that when applying the Bondic, you do so in thin layers in order to insure the application is being completely cured by the UV light as you for obvious reasons would not want it to mix with your gas.

I hope this information has helped. If you have any other questions or concerns please do not hesitate to contact us.

Regards,
The Bondic Team
Title: Re: Fuel pump
Post by: Coldfinger on Dec 22, 2015, 08:08:38 pm
I came across an interesting discussion on a kawasaki atv forum.

They have found a $20 replacement pump for the $400-600 oem pump. 

Caltric is the seller on ebay. 

FUEL PUMP KAWASAKI BRUTE FORCE 750 4X4I / EPS 2008 2009 2010 2011 2012 2013 2014

I wouldnt be surprised if one  wasnt avail for the raider. 
Title: Re: Fuel pump
Post by: Raven on Dec 22, 2015, 08:20:28 pm
I came across an interesting discussion on a kawasaki atv forum.

They have found a $20 replacement pump for the $400-600 oem pump. 

Caltric is the seller on ebay. 

FUEL PUMP KAWASAKI BRUTE FORCE 750 4X4I / EPS 2008 2009 2010 2011 2012 2013 2014

I wouldnt be surprised if one  wasnt avail for the raider.

Caltric also makes starters and from what Ive read on several forums is that they're POS. Yes, certain OEM parts are priced over the top but a $20 replacement pump would make me leary. Sometimes you gotta just bite the bullet and go OEM. I think the fuel pump is one of those parts unfortunately....
Title: Re: Fuel pump
Post by: LeaderDuece on Dec 22, 2015, 09:15:10 pm
If it's the same pump as the Warrior, Armyguy on the Warrior forum found a pump for a Mitsubishi car that works perfectly, and has a higher pump volume to boot. I want to say it was about $120, but it's been a couple of years since I read the post.
Title: Re: Fuel pump
Post by: TheGhostRaider on Mar 12, 2016, 11:50:31 am
I wonder how jb weld would hold up immersed in fuel
Title: Re: Fuel pump
Post by: Ares X on Mar 12, 2016, 12:13:40 pm
I wonder how jb weld would hold up immersed in fuel

I don't think it would hold up well at all.  I use JB Weld to keep the collar to my LA Choppers Profiler cap in place and I think a combination of the gas and the AZ heat make it break loose from time to time.  It's held well for a while now, but I bet if I gave it a good hard twist, I could break it loose again.
Title: Re: Fuel pump
Post by: Zxdave on Mar 12, 2016, 06:23:23 pm
I wonder how jb weld would hold up immersed in fuel

JB weld makes a product called "water weld" that would work good I think... both standard and that are gasoline resistant , but just make sure you sand and prep surfaces good and it would hold !  Me and my brother used it years back on a gas tank for a boat and never had a issue... I also used Jb weld on a 5hp briggs and straton motor that had knocked a hole in the block when I was a teenager , worked great !
Title: Re: Fuel pump
Post by: RonKy on Mar 23, 2016, 12:36:05 pm
I tried everything and looked everywhere for a cheaper alternative for my fuel pump after it cracked.  And yes, even car fuel pumps.  I thought , after all it is a Mitsubishi pump...no such luck. 
Title: Re: Fuel pump
Post by: BK on Mar 24, 2016, 05:11:39 am
I wonder how jb weld would hold up immersed in fuel

If your wanting to use JB weld to fix the crack that happens to the fuel pump, the JB weld will not adhere to the plastic. It may stick at first but it will most likely come lose. Plastic welding is the one thing that might work.
Title: Re: Fuel pump
Post by: BK on Mar 24, 2016, 05:22:24 am
I think you can use the Mitsubishi pumps in our bikes but it is not the pump itself that usually go bad, like Ronky said it is the plastic housing that cracks so we are stuck buying a whole new assembly.
Title: Re: Fuel pump
Post by: Zxdave on Mar 24, 2016, 04:42:58 pm
I wonder how jb weld would hold up immersed in fuel

If your wanting to use JB weld to fix the crack that happens to the fuel pump, the JB weld will not adhere to the plastic. It may stick at first but it will most likely come lose. Plastic welding is the one thing that might work.

That's what  meant by use "jb weld" they make a product called "plasticweld" that's what we used on the boat gas tank and it works great , just prep surface good !

http://www.jbweld.com/products/plasticweld-epoxy-putty
Title: Re: Fuel pump
Post by: Coldfinger on Mar 24, 2016, 07:07:11 pm
Interesting on JB Weld.

Shoot, they have at least 3 different types of plastic weld.   Wow, that looks promising.  Just have to figure out what type of plastic is being repaired. 

I bet JB could tell u how their material holds up to gasoline with up to 10% ethanol.  A phone call.
Title: Re: Fuel pump
Post by: Zxdave on Mar 24, 2016, 07:12:36 pm
Interesting on JB Weld.  Says it doesnt bond to polyethlene or polyproplene.  Not sure what type plastic the pump has.  They have more than one type of plastic weld on their site.  I didnt read about them. 

I bet JB could tell u how their material holds up to gasoline with up to 10% ethanol.  A phone call.

yeah man, def worth a call! cheaper then a new pump housing for sure !!

I don't know what its made of either , but like I said me and my brother used it on a plastic boat tank and held great !
Title: Re: Fuel pump
Post by: NotSoNewbieAnymore on Mar 28, 2016, 01:40:02 pm
Interesting on JB Weld.  Says it doesnt bond to polyethlene or polyproplene.  Not sure what type plastic the pump has.  They have more than one type of plastic weld on their site.  I didnt read about them. 

I bet JB could tell u how their material holds up to gasoline with up to 10% ethanol.  A phone call.

yeah man, def worth a call! cheaper then a new pump housing for sure !!

I don't know what its made of either , but like I said me and my brother used it on a plastic boat tank and held great !

I think I remember from a post that it was Polypropylene.
Title: Re: Fuel pump
Post by: Zxdave on Mar 28, 2016, 06:57:08 pm
Interesting on JB Weld.  Says it doesnt bond to polyethlene or polyproplene.  Not sure what type plastic the pump has.  They have more than one type of plastic weld on their site.  I didnt read about them. 

I bet JB could tell u how their material holds up to gasoline with up to 10% ethanol.  A phone call.

yeah man, def worth a call! cheaper then a new pump housing for sure !!

I don't know what its made of either , but like I said me and my brother used it on a plastic boat tank and held great !

I think I remember from a post that it was Polypropylene.

If so it may not hold then, think the jb weld wont stick to that  :(
Title: Re: Fuel pump
Post by: Boxer on Mar 30, 2016, 05:58:20 pm
Most fuel tanks (gas cans, etc) are High Density Polyethylene (HDPE). There's a bracket on the back of the housing with has more than enough extra material to patch the housing. Its once piece with the housing, so you know its the same material...ergo, it can be used to weld the crack shut. That's what I did and its held for about 3,000 miles thus far.
Title: Re: Fuel pump
Post by: Coldfinger on Mar 30, 2016, 09:20:21 pm
JB Weld Plastic Bonder Syringe specifically says it works on polyproplylene and polyethylene.
Title: Re: Fuel pump
Post by: macph1ms on Dec 20, 2016, 10:46:30 am
I have a 2011 Yamaha Stryker (bought used in 2014 with just 3,200 miles on it). This past summer June 2016 I was traveling about 30mph when the fuel completely cut-off suddenly. Had to have my bike towed to the shop  because of it. Mechanic took the fuel pump out and discovered that fuel was trapped in the top of the fuel pump (made of all white plastic...guh) and that the fuel was going into the sub tank. My stryker at this point had just turned over 9,000 miles. VERY frustrating. No aftermarket equivalent or better was available, so I had to order an OEM fuel pump for $315 part plus labor. I'm just waiting this to happen all over again. I'd be really nice if Yamaha would recall the fuel pump already.
Title: Re: Fuel pump
Post by: Ares X on Dec 20, 2016, 12:33:58 pm
My wife has a 2011 Stryker with 28,000 miles on it and has never had a fuel pump issue. I'm not sure if that's common as I don't visit the Stryker forum very often. It may be worth checking. I think I would question more what the previous owner did with it. If he ran it low on fuel often it could be partially to blame as it could cause the fuel pump to overheat.
Title: Re: Fuel pump
Post by: StrykerBilly on Dec 21, 2016, 07:28:08 am
I have 29K on my Stryker and no fuel pump issues.  There is not a thread on our forum like there is here so assuming it is not a common problem.  But parts do fail and unfortunately the FP is a pricey one :(

As for the low fuel causing this issue on either one, I'm going to have to respectively disagree there.  I'm not saying that people who run it low haven't had FP problems, just that the cause & effect relationship is a little weak.
My logic there is based on simple physics and volume measurements.  Note: numbers I state are for my Stryker since Raider has slightly larger gas tank and wanted to use my numbers.
I don't disagree that the fuel does cool the FP.  It's just that you don't need a lot of it since the FP is in the sub tank and at best holds maybe a pint of gas.  That means on my 4 gallon tank I'd have to be filling up in the 3.85+ range to not have it completely submerged.
Like I said I often run it till the low fuel light comes on and into that range and typically put in maybe up to 3.6 gallons which while close is still 51oz less than 4 gallons and, therefore, plenty to fully cover the FP.
I did wonder if Yamaha just rounded up to 4 gallons for the Stryker but dismissed that since the Raider is listed at 4.2 gallons so they must be fairly accurate.

And as far as how the bike determines when you are at 3/4's and then after that, both bikes are a little wonky IMO.  In my experiences the float can be tricked if you are leaning fairly hard in the corners and sort of low on fuel.  Once that float triggers it seems to go forward from there.  Then again, Maybe Yamaha engineered it to be conservative on purpose to avoid FP heat issues...

Not saying it isn't a good idea to fill up at 3/4's, which I do often, but if we are out riding with a group and it goes past this I don't worry unless I don't know if we are stopping anytime soon!!  I also have a GPS and can quickly scan for gas if we are in unfamiliar territory.

Lastly, cars are different.  Same concept but because gas tanks are much bigger and many shapes the reserve will vary quite a bit and even if you don't run out of gas, your FP could be less than optimally covered in fuel.  My Honda Odyssey is a large flat tank and has this issue.
Title: Re: Fuel pump
Post by: Ares X on Dec 21, 2016, 09:17:14 am
I had that issue with my Firebird and my wife with her Camaro, which were basically the same vehicles for the most part.
Title: Re: Fuel pump
Post by: ROADKILL on Dec 21, 2016, 09:45:25 am
I have 29K on my Stryker and no fuel pump issues.  There is not a thread on our forum like there is here so assuming it is not a common problem.  But parts do fail and unfortunately the FP is a pricey one :(

As for the low fuel causing this issue on either one, I'm going to have to respectively disagree there.  I'm not saying that people who run it low haven't had FP problems, just that the cause & effect relationship is a little weak.
My logic there is based on simple physics and volume measurements.  Note: numbers I state are for my Stryker since Raider has slightly larger gas tank and wanted to use my numbers.
I don't disagree that the fuel does cool the FP.  It's just that you don't need a lot of it since the FP is in the sub tank and at best holds maybe a pint of gas.  That means on my 4 gallon tank I'd have to be filling up in the 3.85+ range to not have it completely submerged.
Like I said I often run it till the low fuel light comes on and into that range and typically put in maybe up to 3.6 gallons which while close is still 51oz less than 4 gallons and, therefore, plenty to fully cover the FP.
I did wonder if Yamaha just rounded up to 4 gallons for the Stryker but dismissed that since the Raider is listed at 4.2 gallons so they must be fairly accurate.

And as far as how the bike determines when you are at 3/4's and then after that, both bikes are a little wonky IMO.  In my experiences the float can be tricked if you are leaning fairly hard in the corners and sort of low on fuel.  Once that float triggers it seems to go forward from there.  Then again, Maybe Yamaha engineered it to be conservative on purpose to avoid FP heat issues...

Not saying it isn't a good idea to fill up at 3/4's, which I do often, but if we are out riding with a group and it goes past this I don't worry unless I don't know if we are stopping anytime soon!!  I also have a GPS and can quickly scan for gas if we are in unfamiliar territory.

Lastly, cars are different.  Same concept but because gas tanks are much bigger and many shapes the reserve will vary quite a bit and even if you don't run out of gas, your FP could be less than optimally covered in fuel.  My Honda Odyssey is a large flat tank and has this issue.
The Raider fuel gauge operates off of the float and the ECU - the float measures the top half of the tank once you reach the 1/2 mark the ECU calculates the remaining fuel based on the previous rate of consumption.
The Raider reserve holds 8 tenths of a gallon - people that have had a FP issue have stated that they have let the tank run low - hence the thought the FP issue could be a heat related issue  :D
Title: Re: Fuel pump
Post by: Ares X on Dec 21, 2016, 09:52:22 am
I have 29K on my Stryker and no fuel pump issues.  There is not a thread on our forum like there is here so assuming it is not a common problem.  But parts do fail and unfortunately the FP is a pricey one :(

As for the low fuel causing this issue on either one, I'm going to have to respectively disagree there.  I'm not saying that people who run it low haven't had FP problems, just that the cause & effect relationship is a little weak.
My logic there is based on simple physics and volume measurements.  Note: numbers I state are for my Stryker since Raider has slightly larger gas tank and wanted to use my numbers.
I don't disagree that the fuel does cool the FP.  It's just that you don't need a lot of it since the FP is in the sub tank and at best holds maybe a pint of gas.  That means on my 4 gallon tank I'd have to be filling up in the 3.85+ range to not have it completely submerged.
Like I said I often run it till the low fuel light comes on and into that range and typically put in maybe up to 3.6 gallons which while close is still 51oz less than 4 gallons and, therefore, plenty to fully cover the FP.
I did wonder if Yamaha just rounded up to 4 gallons for the Stryker but dismissed that since the Raider is listed at 4.2 gallons so they must be fairly accurate.

And as far as how the bike determines when you are at 3/4's and then after that, both bikes are a little wonky IMO.  In my experiences the float can be tricked if you are leaning fairly hard in the corners and sort of low on fuel.  Once that float triggers it seems to go forward from there.  Then again, Maybe Yamaha engineered it to be conservative on purpose to avoid FP heat issues...

Not saying it isn't a good idea to fill up at 3/4's, which I do often, but if we are out riding with a group and it goes past this I don't worry unless I don't know if we are stopping anytime soon!!  I also have a GPS and can quickly scan for gas if we are in unfamiliar territory.

Lastly, cars are different.  Same concept but because gas tanks are much bigger and many shapes the reserve will vary quite a bit and even if you don't run out of gas, your FP could be less than optimally covered in fuel.  My Honda Odyssey is a large flat tank and has this issue.
The Raider fuel gauge operates off of the float and the ECU - the float measures the top half of the tank once you reach the 1/2 mark the ECU calculates the remaining fuel based on the previous rate of consumption.
The Raider reserve holds 8 tenths of a gallon - people that have had a FP issue have stated that they have let the tank run low - hence the thought the FP issue could be a heat related issue  :D

I was one of them and definitely remember letting it run very low and once even completely out (wasn't paying attention) and I live in AZ, so heat could be an issue.
Title: Re: Fuel pump
Post by: CHROMINATOR on Dec 21, 2016, 09:52:58 am
I have 29K on my Stryker and no fuel pump issues.  There is not a thread on our forum like there is here so assuming it is not a common problem.  But parts do fail and unfortunately the FP is a pricey one :(

As for the low fuel causing this issue on either one, I'm going to have to respectively disagree there.  I'm not saying that people who run it low haven't had FP problems, just that the cause & effect relationship is a little weak.
My logic there is based on simple physics and volume measurements.  Note: numbers I state are for my Stryker since Raider has slightly larger gas tank and wanted to use my numbers.
I don't disagree that the fuel does cool the FP.  It's just that you don't need a lot of it since the FP is in the sub tank and at best holds maybe a pint of gas.  That means on my 4 gallon tank I'd have to be filling up in the 3.85+ range to not have it completely submerged.
Like I said I often run it till the low fuel light comes on and into that range and typically put in maybe up to 3.6 gallons which while close is still 51oz less than 4 gallons and, therefore, plenty to fully cover the FP.
I did wonder if Yamaha just rounded up to 4 gallons for the Stryker but dismissed that since the Raider is listed at 4.2 gallons so they must be fairly accurate.

And as far as how the bike determines when you are at 3/4's and then after that, both bikes are a little wonky IMO.  In my experiences the float can be tricked if you are leaning fairly hard in the corners and sort of low on fuel.  Once that float triggers it seems to go forward from there.  Then again, Maybe Yamaha engineered it to be conservative on purpose to avoid FP heat issues...

Not saying it isn't a good idea to fill up at 3/4's, which I do often, but if we are out riding with a group and it goes past this I don't worry unless I don't know if we are stopping anytime soon!!  I also have a GPS and can quickly scan for gas if we are in unfamiliar territory.

Lastly, cars are different.  Same concept but because gas tanks are much bigger and many shapes the reserve will vary quite a bit and even if you don't run out of gas, your FP could be less than optimally covered in fuel.  My Honda Odyssey is a large flat tank and has this issue.

With the Raider it's not the fuel pump that has the problem, it's the housing that is around the fuel pump.  A crack develops and fuel pressure is lost.  The only bad thing about this problem is that you can't order just the housing.  It's sold as a unit which includes the housing and the fuel pump which if I am not mistaken is over $400.00.  The only ones I can recall that have had a problem all have the crack and it's in the same place on the housing.  Some have had success repairing the crack while others have not.  All that have had the problem have said that they allow the reserve light to come on before refueling.  I am not saying that is a definite cause but for those that don't let the reserve light come on like me have had no issue with the housing cracking.  It does give pause for thought.
Title: Re: Fuel pump
Post by: StrykerBilly on Dec 21, 2016, 10:42:15 am
I have 29K on my Stryker and no fuel pump issues.  There is not a thread on our forum like there is here so assuming it is not a common problem.  But parts do fail and unfortunately the FP is a pricey one :(

As for the low fuel causing this issue on either one, I'm going to have to respectively disagree there.  I'm not saying that people who run it low haven't had FP problems, just that the cause & effect relationship is a little weak.
My logic there is based on simple physics and volume measurements.  Note: numbers I state are for my Stryker since Raider has slightly larger gas tank and wanted to use my numbers.
I don't disagree that the fuel does cool the FP.  It's just that you don't need a lot of it since the FP is in the sub tank and at best holds maybe a pint of gas.  That means on my 4 gallon tank I'd have to be filling up in the 3.85+ range to not have it completely submerged.
Like I said I often run it till the low fuel light comes on and into that range and typically put in maybe up to 3.6 gallons which while close is still 51oz less than 4 gallons and, therefore, plenty to fully cover the FP.
I did wonder if Yamaha just rounded up to 4 gallons for the Stryker but dismissed that since the Raider is listed at 4.2 gallons so they must be fairly accurate.

And as far as how the bike determines when you are at 3/4's and then after that, both bikes are a little wonky IMO.  In my experiences the float can be tricked if you are leaning fairly hard in the corners and sort of low on fuel.  Once that float triggers it seems to go forward from there.  Then again, Maybe Yamaha engineered it to be conservative on purpose to avoid FP heat issues...

Not saying it isn't a good idea to fill up at 3/4's, which I do often, but if we are out riding with a group and it goes past this I don't worry unless I don't know if we are stopping anytime soon!!  I also have a GPS and can quickly scan for gas if we are in unfamiliar territory.

Lastly, cars are different.  Same concept but because gas tanks are much bigger and many shapes the reserve will vary quite a bit and even if you don't run out of gas, your FP could be less than optimally covered in fuel.  My Honda Odyssey is a large flat tank and has this issue.
The Raider fuel gauge operates off of the float and the ECU - the float measures the top half of the tank once you reach the 1/2 mark the ECU calculates the remaining fuel based on the previous rate of consumption.
The Raider reserve holds 8 tenths of a gallon - people that have had a FP issue have stated that they have let the tank run low - hence the thought the FP issue could be a heat related issue  :D

OK this just falls in the "Inquiry minds what to know" category but by "reserve" are you referring to the sub tank under the seat?  If so I'm having a hard time wrapping my head around the 8/10th's of a gallon figure since that would be just smaller than a gallon of milk which I cannot see fitting in there at all.
But to be totally honest I've only seen what I think is the top of it on my bike and hope to never have to fully remove it!!  Could be the part is a lot bigger than I think it is...
Title: Re: Fuel pump
Post by: ROADKILL on Dec 21, 2016, 11:12:19 am
I have 29K on my Stryker and no fuel pump issues.  There is not a thread on our forum like there is here so assuming it is not a common problem.  But parts do fail and unfortunately the FP is a pricey one :(

As for the low fuel causing this issue on either one, I'm going to have to respectively disagree there.  I'm not saying that people who run it low haven't had FP problems, just that the cause & effect relationship is a little weak.
My logic there is based on simple physics and volume measurements.  Note: numbers I state are for my Stryker since Raider has slightly larger gas tank and wanted to use my numbers.
I don't disagree that the fuel does cool the FP.  It's just that you don't need a lot of it since the FP is in the sub tank and at best holds maybe a pint of gas.  That means on my 4 gallon tank I'd have to be filling up in the 3.85+ range to not have it completely submerged.
Like I said I often run it till the low fuel light comes on and into that range and typically put in maybe up to 3.6 gallons which while close is still 51oz less than 4 gallons and, therefore, plenty to fully cover the FP.
I did wonder if Yamaha just rounded up to 4 gallons for the Stryker but dismissed that since the Raider is listed at 4.2 gallons so they must be fairly accurate.

And as far as how the bike determines when you are at 3/4's and then after that, both bikes are a little wonky IMO.  In my experiences the float can be tricked if you are leaning fairly hard in the corners and sort of low on fuel.  Once that float triggers it seems to go forward from there.  Then again, Maybe Yamaha engineered it to be conservative on purpose to avoid FP heat issues...

Not saying it isn't a good idea to fill up at 3/4's, which I do often, but if we are out riding with a group and it goes past this I don't worry unless I don't know if we are stopping anytime soon!!  I also have a GPS and can quickly scan for gas if we are in unfamiliar territory.

Lastly, cars are different.  Same concept but because gas tanks are much bigger and many shapes the reserve will vary quite a bit and even if you don't run out of gas, your FP could be less than optimally covered in fuel.  My Honda Odyssey is a large flat tank and has this issue.
The Raider fuel gauge operates off of the float and the ECU - the float measures the top half of the tank once you reach the 1/2 mark the ECU calculates the remaining fuel based on the previous rate of consumption.
The Raider reserve holds 8 tenths of a gallon - people that have had a FP issue have stated that they have let the tank run low - hence the thought the FP issue could be a heat related issue  :D

OK this just falls in the "Inquiry minds what to know" category but by "reserve" are you referring to the sub tank under the seat?  If so I'm having a hard time wrapping my head around the 8/10th's of a gallon figure since that would be just smaller than a gallon of milk which I cannot see fitting in there at all.
But to be totally honest I've only seen what I think is the top of it on my bike and hope to never have to fully remove it!!  Could be the part is a lot bigger than I think it is...
Yes the reserve is the sub tank under the seat.
Here's a link scroll down to Additional Features http://www.totalmotorcycle.com/motorcycles/2012models/2012-Yamaha-Raider.htm
"Low-fuel warning light (activated with 3 litres of fuel remaining)" = .79 gals  :nerd:
Title: Re: Fuel pump
Post by: mrwhtfks on Feb 09, 2017, 08:06:33 am
Can anyone guess what I was doing last night?!?!  Only lost the finger print on one finger too, I will call that a win! 

It is amazing to me how perfectly similar my crack is with almost EVERY other fuel pump crack picture I have seen off this site.  I just can't believe Yamaha wont step in and do the right thing.  Probably cause its a $500 part! 
Title: Re: Fuel pump
Post by: CHROMINATOR on Feb 09, 2017, 08:31:51 am
It is amazing that they won't acknowledge there is a problem with the housing.  I guess they don't know how to do an internet search...  :o  Any time I do for this problem there are pages and pages covering this subject.
Title: Re: Fuel pump
Post by: t84a on Feb 09, 2017, 10:19:55 am
Can anyone guess what I was doing last night?!?!  Only lost the finger print on one finger too, I will call that a win! 

It is amazing to me how perfectly similar my crack is with almost EVERY other fuel pump crack picture I have seen off this site.  I just can't believe Yamaha wont step in and do the right thing.  Probably cause its a $500 part!

What year is your bike?  I'm told the fuel pump is covered for 5 years under the emissions warranty. 
Title: Re: Fuel pump
Post by: mrwhtfks on Feb 10, 2017, 07:42:27 am
2008   >:(

Got it all back together yesterday and took a test  :raider:  Bike right away was MUCH easier to start, MUCH less sputter and back fire.  Also even had the fuel light come on and no drop in performance (used to run AWFUL when it was even 1/4 of a tank).  Did not get it on the highway to see if the hesitation is gone, but I would say this is fixed!  Wanted to get it done now and test out for a while before I head up to the NC mountains for the SERR in July.
Title: Re: Fuel pump
Post by: CHROMINATOR on Feb 10, 2017, 09:06:25 am
Glad you got it fixed, hopefully it will last...  :fingerscrossed:
Title: Re: Fuel pump
Post by: mrwhtfks on Feb 10, 2017, 07:32:23 pm
Glad you got it fixed, hopefully it will last...  :fingerscrossed:

You took the words right out of my mouth.
Title: Re: Fuel pump
Post by: ROADKILL on Feb 10, 2017, 09:48:35 pm
2008   >:(

Got it all back together yesterday and took a test  :raider:  Bike right away was MUCH easier to start, MUCH less sputter and back fire.  Also even had the fuel light come on and no drop in performance (used to run AWFUL when it was even 1/4 of a tank).  Did not get it on the highway to see if the hesitation is gone, but I would say this is fixed!  Wanted to get it done now and test out for a while before I head up to the NC mountains for the SERR in July.
:thumbs:
Title: Re: Fuel pump
Post by: 182PC on Feb 14, 2017, 06:44:00 am
I am trying to rescue an 09 Raider left parked for 4 to 5 years. Going through fuel system. What is the best way to clean fuel pump? It pumps with no leaks. I have not checked the pressure. I have it out of the tank. Can I soak it in carb cleaner?
Title: Re: Fuel pump
Post by: ROADKILL on Feb 14, 2017, 08:54:38 am
I am trying to rescue an 09 Raider left parked for 4 to 5 years. Going through fuel system. What is the best way to clean fuel pump? It pumps with no leaks. I have not checked the pressure. I have it out of the tank. Can I soak it in carb cleaner?
That or give it a bath in Seafoam - glad you rescued an abused  >:( Raider
Title: Re: Fuel pump
Post by: Ares X on Feb 14, 2017, 09:41:29 am
I am trying to rescue an 09 Raider left parked for 4 to 5 years. Going through fuel system. What is the best way to clean fuel pump? It pumps with no leaks. I have not checked the pressure. I have it out of the tank. Can I soak it in carb cleaner?

Good for you!  I hope you reported the previous owner to the authorities for abusing an innocent motorcycle.  I need to do the same for a guy down the street that leaves his outside in the driveway all the time.
Title: Re: Fuel pump
Post by: 182PC on Feb 14, 2017, 07:16:43 pm
Well, the guy got ill, and then progressively has gotten worse. He approached me about rescuing it, and then made a deal with me that I couldn't refuse. He is almost as pumped about seeing it run again as I am. Sorry if I said something that was misleading. Now I have the tanks out to be cleaned and lined. I just need to find the best way to clean the pump without ruining the plastic., and clearing the line from the pump to the injectors. Any suggestions? Or any other things that I need to do?
Title: Re: Fuel pump
Post by: Ares X on Feb 14, 2017, 07:19:37 pm
I was only joking and I think since he's been ill we'll cut him some slack.  GOOD LUCK!
Title: Re: Fuel pump
Post by: 182PC on Feb 14, 2017, 07:33:59 pm
Not a problem. I have to put new rubber on it also. What seems to be the most used? Going to 240. I know this can be quite controversial but looking at Avon and Dunlop.
Title: Re: Fuel pump
Post by: Ares X on Feb 14, 2017, 07:36:40 pm
Probably about 90% of the people here are going to tell you Avon 240.  Fronts are okay with the stock Metz, but if you're replacing both you may as well get a matching set.
Title: Re: Fuel pump
Post by: mrwhtfks on Feb 16, 2017, 10:22:57 am
I am trying to rescue an 09 Raider left parked for 4 to 5 years. Going through fuel system. What is the best way to clean fuel pump? It pumps with no leaks. I have not checked the pressure. I have it out of the tank. Can I soak it in carb cleaner?

This is a good video about the fuel pump issues these things have.  However it could be useful in your case.  At about the 5 minute mark he shows you the electrical connections on how to get the pump to turn jumping it off the battery.  Since you have it out of the bike you can put the pump in a tubberware or the like and flush it using the pump itself.  Make sure you get all that nasty out of it.  He does just that in the video at about the 8:30 mark. 

https://www.youtube.com/watch?v=jKaqwBeV1Vw

And I will be one of the 90% telling you to go Avon.  Switched to it about 3 months ago and COULD not be happier.
Title: Re: Fuel pump
Post by: 182PC on Feb 16, 2017, 06:59:18 pm
Thanks for the info. What should I flush it with? Straight Sea Foam?. I thought about a can of carburetor soak, like you can buy at an auto store. A bit worried about harming the plastic. It already sounds like the fuel pumps have a problem with that.
Title: Re: Fuel pump
Post by: diamondlou78 on Nov 26, 2017, 09:24:34 pm
I think my new (to me) 08 9kmi has the cracked fuel pump.
1. Would you reccomend doing the repair or just getting a new pump? (seems like a new pump housing would fail the same just a matter of time?)
2. I saw drilling the ends of the crack before sealing/welding would be a good idea?
3. Have the folks had to touch up the repair after a period of time and how long?
Title: Re: Fuel pump
Post by: A.T. on Nov 27, 2017, 06:01:17 am
Replace 100%.  But what makes you think it's the pump?
Title: Re: Fuel pump
Post by: Kevs UK Raider SCL on Nov 27, 2017, 10:41:48 am
I think my new (to me) 08 9kmi has the cracked fuel pump.
1. Would you reccomend doing the repair or just getting a new pump? (seems like a new pump housing would fail the same just a matter of time?)
2. I saw drilling the ends of the crack before sealing/welding would be a good idea?
3. Have the folks had to touch up the repair after a period of time and how long?

Which is it? The fuel pump or the fuel pump housing. The fuel pump is relatively cheap to replace but the housing is expensive. Many have tried to repair the housing but it doesn't last very long, and eventually it needs replacing.
Title: Re: Fuel pump
Post by: ROADKILL on Nov 27, 2017, 11:15:19 am
I think my new (to me) 08 9kmi has the cracked fuel pump.
1. Would you reccomend doing the repair or just getting a new pump? (seems like a new pump housing would fail the same just a matter of time?)
2. I saw drilling the ends of the crack before sealing/welding would be a good idea?
3. Have the folks had to touch up the repair after a period of time and how long?

Which is it? The fuel pump or the fuel pump housing. The fuel pump is relatively cheap to replace but the housing is expensive. Many have tried to repair the housing but it doesn't last very long, and eventually it needs replacing.
The fuel pump and housing are all one unit - nobody has been able to find the housing sold separately.
Title: Re: Fuel pump
Post by: woodog on Dec 03, 2017, 06:24:30 pm
Anyone needing a new OEM pump....PM me....

Title: Re: Fuel pump
Post by: Fiddles on Dec 05, 2017, 12:32:57 pm
 Its that for the complete assembly?
Title: Re: Fuel pump
Post by: woodog on Dec 05, 2017, 06:55:40 pm
Its that for the complete assembly?






Complete...
Title: Re: Fuel pump
Post by: RuneRaider on Dec 12, 2017, 11:21:34 pm
Interested as I might need to restore my fuel system. I really need to get old girl fired back up again. Guilty as charged.
Title: Re: Fuel pump
Post by: Silver Bullet on Oct 06, 2018, 06:44:29 pm
I think my new (to me) 08 9kmi has the cracked fuel pump.
1. Would you reccomend doing the repair or just getting a new pump? (seems like a new pump housing would fail the same just a matter of time?)
2. I saw drilling the ends of the crack before sealing/welding would be a good idea?
3. Have the folks had to touch up the repair after a period of time and how long?

Which is it? The fuel pump or the fuel pump housing. The fuel pump is relatively cheap to replace but the housing is expensive. Many have tried to repair the housing but it doesn't last very long, and eventually it needs replacing.

I had mine replaced right before my warranty ran out.  This week its cut off on me twice when pulling up to red lights and started sputtering and popping more.  I am guessing the new one is failing now.
Title: Re: Fuel pump
Post by: A.T. on Oct 07, 2018, 08:53:33 am
I think my new (to me) 08 9kmi has the cracked fuel pump.
1. Would you reccomend doing the repair or just getting a new pump? (seems like a new pump housing would fail the same just a matter of time?)
2. I saw drilling the ends of the crack before sealing/welding would be a good idea?
3. Have the folks had to touch up the repair after a period of time and how long?

Which is it? The fuel pump or the fuel pump housing. The fuel pump is relatively cheap to replace but the housing is expensive. Many have tried to repair the housing but it doesn't last very long, and eventually it needs replacing.

I had mine replaced right before my warranty ran out.  This week its cut off on me twice when pulling up to red lights and started sputtering and popping more.  I am guessing the new one is failing now.

How many miles on the replacement pump?   
Title: Re: Fuel pump
Post by: Coldfinger on Feb 13, 2019, 09:15:52 am
I am passing along information which might help repair cracked fuel housings.

Here is bonding material information from my recent discussions with J-B Weld/Fiber Fix.

I was repairing a cracked tank filler neck on my snowmobile and asked J-B and Fiber Fix what they would recommend.  I learned from the Fiber Fix reply that they are essentially the same company and he recommended the J-B Weld for the snowmobile tank repair.

Here is a summary of what they said:  J-B Weld Plastic Bonder would be the best product for repairing the snowmobile tank filler neck.
That is the product I used but didn't get a chance to see how well it might work if allowed to cure more than a few hours because it was a quick fix and then exposed to sub-freezing temps for days.  I dropped the sled off at dealer after I was done riding and the factory is paying to replace the defective tank.

Then I asked about using Fiber Fix (Flex Patch or Rigid Patch) for repairing a fuel pump housing submerged in fuel and they said:
In regards to fuel resistance, we have not tested the Flex Patch on it. I would imagine the Rigid Patch would hold up better against fuel than the Flex Patch, but again if the plastic housing flexes a lot then you'll want the Flex Patch instead.

My thoughts -
I don't know how much the housing flexes.  I would suspect a little, and probably flexes more if the sub-tank is running low because there is less fuel on outside of housing, ie, less pressure on outside of housing.  If previously stated observations are correct, people tend to experience cracked housings at a higher rate if they regularly run with the low fuel light on.

If I have to repair a crack in my housing, first thing I might do is test the J-B Weld plastic bonder for fuel resistance.  Mainly because I already have some and it will not cost anything.   If it is fuel resistant, I think I would apply some, let it dry, sand it, then apply some more and place a section of aluminum screen material on or around (if possible) and apply some more and let it cure.

If that doesn't work, I would test the Fiber Fix Rigid Patch for fuel resistance, and if it is, then use that.  Especially if one can wrap the pump housing rather than applying only a patch.

If one thinks there is or will be flexing of the repair area even after the repair, the Fiber Fix Flex Patch would be my choice.
Title: Re: Fuel pump
Post by: Fasttimez on Feb 18, 2019, 05:22:19 am
I am passing along information which might help repair cracked fuel housings.

Here is bonding material information from my recent discussions with J-B Weld/Fiber Fix.

I was repairing a cracked tank filler neck on my snowmobile and asked J-B and Fiber Fix what they would recommend.  I learned from the Fiber Fix reply that they are essentially the same company and he recommended the J-B Weld for the snowmobile tank repair.

Here is a summary of what they said:  J-B Weld Plastic Bonder would be the best product for repairing the snowmobile tank filler neck.
That is the product I used but didn't get a chance to see how well it might work if allowed to cure more than a few hours because it was a quick fix and then exposed to sub-freezing temps for days.  I dropped the sled off at dealer after I was done riding and the factory is paying to replace the defective tank.

Then I asked about using Fiber Fix (Flex Patch or Rigid Patch) for repairing a fuel pump housing submerged in fuel and they said:
In regards to fuel resistance, we have not tested the Flex Patch on it. I would imagine the Rigid Patch would hold up better against fuel than the Flex Patch, but again if the plastic housing flexes a lot then you'll want the Flex Patch instead.

My thoughts -
I don't know how much the housing flexes.  I would suspect a little, and probably flexes more if the sub-tank is running low because there is less fuel on outside of housing, ie, less pressure on outside of housing.  If previously stated observations are correct, people tend to experience cracked housings at a higher rate if they regularly run with the low fuel light on.

If I have to repair a crack in my housing, first thing I might do is test the J-B Weld plastic bonder for fuel resistance.  Mainly because I already have some and it will not cost anything.   If it is fuel resistant, I think I would apply some, let it dry, sand it, then apply some more and place a section of aluminum screen material on or around (if possible) and apply some more and let it cure.

If that doesn't work, I would test the Fiber Fix Rigid Patch for fuel resistance, and if it is, then use that.  Especially if one can wrap the pump housing rather than applying only a patch.

If one thinks there is or will be flexing of the repair area even after the repair, the Fiber Fix Flex Patch would be my choice.
The problem with any of the plastic bond/repair materials that are designed for fuel, is that they aren't designed to withstand constant pressure.  Sure a material designed to repair a gas tank will hold up well to the static weight of the gasoline in the tank, but when you throw a constant 40+ PSI of pressure to it, it won't last long.  I tried every type of plastic repair/bonding agent to fix mine.  They all lasted about 500-1000 miles before the pressure blew a hole right through it.  The best fix I tried was using another piece of plastic (cut from an old gas jug) & bonding it over the area that was cracked.  But it still failed.....my advice is, if you have a cracked housing just go ahead & save yourself the time & get a good used one or a new one.   
Title: Re: Fuel pump
Post by: marcelmot on Feb 19, 2019, 06:01:27 am
Just "out of the box" thinking :

what if we put 2 or 3 metal ring clamps, over the plastic body of the fuel pump assy ..... as a preventive action ??




Title: Re: Fuel pump
Post by: Fasttimez on Feb 19, 2019, 08:40:27 am
Just "out of the box" thinking :

what if we put 2 or 3 metal ring clamps, over the plastic body of the fuel pump assy ..... as a preventive action ??
I cut open my old cracked pump body.  It's a manufacturing flaw......where it cracked, the material on the inside of the cracked spot was noticeably thinner than anywhere else on the pump body.  Using clamps I doubt would prevent it from eventually happening due to this.  But it's certainly not gonna hurt either.  When I did my first repair, I actually used about 6 metal zip ties, but it didn't hold.  It blew right thru the repaired area anyway.  The pump fits VERY tight into the sub tank, I doubt you could get the pump back in the tank because of the clearance issues from the screw part of the clamp.  I barely was able to fit the pump back in with the zip tie ends protruding the little amount.   
Title: Re: Fuel pump
Post by: ROADKILL on Feb 19, 2019, 09:19:35 am
The only good thing about the fuel pump is they are now less than $500 - found them @ Partzilla for $476.00
Title: Re: Fuel pump
Post by: woodog on Feb 19, 2019, 09:54:07 am
The only good thing about the fuel pump is they are now less than $500 - found them @ Partzilla for $476.00










I can get OEM brand new Fuel pumps in box for 350 plus shipping
Title: Re: Fuel pump
Post by: FireNative on Feb 19, 2019, 01:10:43 pm
The only good thing about the fuel pump is they are now less than $500 - found them @ Partzilla for $476.00

From where? Web site link please.








I can get OEM brand new Fuel pumps in box for 350 plus shipping
Title: Re: Fuel pump
Post by: ROADKILL on Feb 19, 2019, 01:19:02 pm
The only good thing about the fuel pump is they are now less than $500 - found them @ Partzilla for $476.00

From where? Web site link please.








I can get OEM brand new Fuel pumps in box for 350 plus shipping
He has connections
Title: Re: Fuel pump
Post by: the urban legend on Feb 19, 2019, 06:59:34 pm
I have a fix for this issue. It doesn't involve patching up anything. I wasn't able to test it out on the road before winter came,but it works perfectly in the shed.

On January 2nd,I finished creating a full how-to write up with pictures and everything. I was about to post it but my 37 day old HP PC decided to crap out big time. Among other issues,the document was impossible to open,I couldn't move it to any other folder,creating a backup copy was impossible... I soon realized that the same illness afflicted my pictures and my music. Every day for weeks I tried to move the document to an external storage device. I also tried opening it,hoping that maybe I could take screenshots and save those somehow.  One time I clicked on the document and let the PC run while I was away. 26 hours later it was still working on it. I finally gave in and called tech support. First they tried a few tests but everything was normal. Then they reset my PC to factory condition...deleting all of my files in the process. And you know what? The damn PC still ran like crap. I had a good 30 hours of work in that How-to;writing,cropping and adding text to pictures,putting everything together so it was clear and made sense,proof reading,modifying... I just haven't had the heart to do it all over again.

 The PC is currently at the HP service center. It's been a week and I haven't heard back from them yet. Honestly,I don't even want to see it anymore. Unfortunately warranty policy states that they will fix it and send it back. But let me tell you,if I hadn't coughed up $800 for the damn thing I'd be making one of those "object VS 20 ton press" videos as soon as I got it back.
   :rant:
Title: Re: Fuel pump
Post by: A.T. on Feb 19, 2019, 07:55:05 pm
Well Marc - that just sux.

My .02:  It's better to replace the pump assembly; repairs only delay the inevitable   Introducing foreign materials that are submerged in fuel is asking for trouble.  Fiberglass isn't an option when using ethanol fuel, and most bonding materials will dissolve in petrol.   Dissimilar metals in fuel is probably unwise - God knows what electrical capacitance issues may come into play if not bonded - one spark and.... 

Replacement is not a difficult job and can be done in less than 90 mins by someone who is mechanically competent possessing the needed tools.

One good thing is this pump is somewhat a universal Yamaha item - it's also used with Yamaha outboards (not keyboards  ;D).
Title: Re: Fuel pump
Post by: Phaedrus on Feb 20, 2019, 08:59:32 am
Fiberglass isn't an option when using ethanol fuel, and most bonding materials will dissolve in petrol.   Dissimilar metals in fuel is probably unwise - God knows what electrical capacitance issues may come into play if not bonded - one spark and.... 
:popcorn:
Title: Re: Fuel pump
Post by: ROADKILL on Feb 20, 2019, 09:48:28 am
I think that the only way that you could repair the crack that would last for a while would be on the inside which would be a real PITA.
Title: Re: Fuel pump
Post by: StrykerBilly on Feb 20, 2019, 10:14:38 am
I have a fix for this issue. It doesn't involve patching up anything. I wasn't able to test it out on the road before winter came,but it works perfectly in the shed.

On January 2nd,I finished creating a full how-to write up with pictures and everything. I was about to post it but my 37 day old HP PC decided to crap out big time. Among other issues,the document was impossible to open,I couldn't move it to any other folder,creating a backup copy was impossible... I soon realized that the same illness afflicted my pictures and my music. Every day for weeks I tried to move the document to an external storage device. I also tried opening it,hoping that maybe I could take screenshots and save those somehow.  One time I clicked on the document and let the PC run while I was away. 26 hours later it was still working on it. I finally gave in and called tech support. First they tried a few tests but everything was normal. Then they reset my PC to factory condition...deleting all of my files in the process. And you know what? The damn PC still ran like crap. I had a good 30 hours of work in that How-to;writing,cropping and adding text to pictures,putting everything together so it was clear and made sense,proof reading,modifying... I just haven't had the heart to do it all over again.

 The PC is currently at the HP service center. It's been a week and I haven't heard back from them yet. Honestly,I don't even want to see it anymore. Unfortunately warranty policy states that they will fix it and send it back. But let me tell you,if I hadn't coughed up $800 for the damn thing I'd be making one of those "object VS 20 ton press" videos as soon as I got it back.
   :rant:

Sadly most of the mfg's riddle the laptops with so much bloatware that they are practically useless.  Varies from one to the other and year top year so you just have to look when you get it and see if just removing their programs fixes things.  If not, then I do a clean reload of Windows.  It's extra work for sure but the machines run much better.

I also ALWAYS partition the hard drive(better yet a SSD as they are now inexpensive) to have a C and D partition.  D is for data and where all of that goes.  Later on if Windows takes a crap you can reload to the C partition and not affect your data.  And goes without saying to backup the data partition regularly.  I use free software that runs every other night and backs up to our NAS device.  You could also use the cloud but that can get a little costly if you have a lot of data.

HP also has a nasty habit of white listing things like wifi cards in the bios.  What that means is you can only use theirs and you cannot say upgrade to wireless AC.  Planned obsolesce I guess...  Plus their customer service blows but in fairness most do.

My daughters college laptop was/is terrible but she was years behind on applying updates.  Not sure how she managed that but she did.  Took days for it to update on a speedy hard wired connection but now that is good.  Wifi, though is terrible.  Research new cards since Dell does not white list.  Worth trying for say $40 and time because her teacher laptop is locked down so you cannot add any programs or even a font for a project :(
Her old laptop will only perform like the 2014 machine that it is but sure beats shelling out $800 if you don't have too!  Eventually they all need to be replaced but some small changes can eek out an extra 3-4 years if you don't need it to be super snappy.  More $$'s to spend on the motorcycle!!
Title: Re: Fuel pump
Post by: Ares X on Feb 20, 2019, 12:14:32 pm
Well Marc - that just sux.

My .02:  It's better to replace the pump assembly; repairs only delay the inevitable   Introducing foreign materials that are submerged in fuel is asking for trouble.  Fiberglass isn't an option when using ethanol fuel, and most bonding materials will dissolve in petrol.   Dissimilar metals in fuel is probably unwise - God knows what electrical capacitance issues may come into play if not bonded - one spark and.... 

Replacement is not a difficult job and can be done in less than 90 mins by someone who is mechanically competent possessing the needed tools.

One good thing is this pump is somewhat a universal Yamaha item - it's also used with Yamaha outboards (not keyboards  ;D).

I agree about replacing being the better way to go.  I replaced it twice on my first Raider. Both at about 30,000 miles of use. Luckily Yamaha picked up the bill on the second one.
Title: Re: Fuel pump
Post by: the urban legend on Feb 20, 2019, 07:09:05 pm
--First ,I didn't use any material that wasn't designed for gasoline use. I've been looking into this for a while. My housing wasn't cracked,but I wanted to do something for all the victims out there. And it'll probably happen to me someday anyway,so might as well get a jump on it. I got a cracked housing from fellow forum member Tice like 3 years ago and I've been working on a viable solution since then. But nothing fit until now.
--Second,like I said earlier I didn't patch anything. I actually cut the housing up,leaving only what I needed. Actually,I left more than I needed just to guarantee structural integrity.
--Third,this mod basically takes the housing out of the equation. If it works as intended,that's one less problem area on an already very reliable motorcycle.

I wanted to post the how-to in January,even untested out on the road,in case somebody needed it during winter.But now I'm thinking I should ride with it all summer and post only next fall or winter. Your skepticism has fueled my procrastination  ;)
Title: Re: Fuel pump
Post by: A.T. on Feb 20, 2019, 07:56:50 pm
--First ,I didn't use any material that wasn't designed for gasoline use. I've been looking into this for a while. My housing wasn't cracked,but I wanted to do something for all the victims out there. And it'll probably happen to me someday anyway,so might as well get a jump on it. I got a cracked housing from fellow forum member Tice like 3 years ago and I've been working on a viable solution since then. But nothing fit until now.
--Second,like I said earlier I didn't patch anything. I actually cut the housing up,leaving only what I needed. Actually,I left more than I needed just to guarantee structural integrity.
--Third,this mod basically takes the housing out of the equation. If it works as intended,that's one less problem area on an already very reliable motorcycle.

I wanted to post the how-to in January,even untested out on the road,in case somebody needed it during winter.But now I'm thinking I should ride with it all summer and post only next fall or winter. Your skepticism has fueled my procrastination  ;)

 ;D....Marc - we wouldn't expect anything less from you when a challenge arises.  Skepticism?  Never when you're involved.   

I have two extra pumps assemblies in my garage - one is my original cracked pump while the other is a used pump I picked up along the way as a back-up.  Definitely would want to see your solution, maybe try it out on my bad pump. 

On planes with jet fuel we used a two-part sealant called 899-B1/2 (or B2) for sealing fuel tanks.  That stuff worked with JP8 (kerosine) - not sure if it would hold up to ethanol petrol. 
Title: Re: Fuel pump
Post by: twiztted on May 22, 2019, 07:55:45 pm
I just pulled my fuel pump out and have the notorious crack!  Is there anyway to fix or repair the pump at a resonable cost?  $400+ is crazy expensive and that kind of cost hurts bad!  Is there another pump that can be used that doesnt have the housing crack issue? I've seen other "replacement pumps" for far less but I'm not a mechanic and I'm not sure if they would work. Any help would be hugley appreciated
Title: Re: Fuel pump
Post by: the urban legend on May 22, 2019, 08:18:54 pm
I just pulled my fuel pump out and have the notorious crack!  Is there anyway to fix or repair the pump at a resonable cost?  $400+ is crazy expensive and that kind of cost hurts bad!  Is there another pump that can be used that doesnt have the housing crack issue? I've seen other "replacement pumps" for far less but I'm not a mechanic and I'm not sure if they would work. Any help would be hugley appreciated

The problem with replacing the pump is that you're still stuck with the cracked housing. Don't waste your money on a pump if the problem is the housing. Even a brand new aftermarket pump won't produce the required pressure if the housing leaks.

My suggestion if you can't throw money at a new pump/housing assembly: try to plastic weld it. At this point you have nothing to lose. Some people have gotten a few thousand miles out of a welded housing before the crack reappeared. In the meantime,I might get the time (and willpower) to redo my pump housing mod how-to. I've been consistently working 10-12 hour days for the last few months so time is at a premium for me right now.

Another suggestion: try sending woodog a PM. Apparently he has a good price on new housings.
Title: Re: Fuel pump
Post by: sundancer87 on May 26, 2019, 06:38:58 pm
I don't have this problem yet but I have been reading the threads about the possible repairs and replacement cost. 
There are inline fuel pumps capable of delivering high pressure for EFI engines, up to 1200 BHP.  Why couldn't one just replace the 500 dollar pump with a 30 dollar pump.  The aforementioned pump does not need to be submerged and comes with normal fittings.
I haven't had the Raider's tank off but I'm sure a few modifications could be made and the pump located to a suitable place and would service the engine just fine.  If they can work in automobiles I don't see why they won't work on a Raider.  As an example; https://www.ebay.com/itm/Inline-High-Pressure-Fuel-Pump-Universal-Replacement-Bosch-0580464070-MegaSquirt-/332097664392?_trksid=p2349526.m4383.l4275.c10#viTabs_0
Title: Re: Fuel pump
Post by: Coldfinger on Jun 11, 2019, 01:46:24 pm
I would apply plastic bonder to the crack, then wrap the housing using fiber fix. 

I have some JB Weld Plastic Bonder which They recommended for such repairs and Fiber Fix told me their product is fuel resistant but untested in submersion. 

If anyone is willing to consider this method, I would be glad to apply plastic bonder to some plastic and place the piece in 10% ethanol and do the same in non-ethanol to get a rough idea if it would even be a consideration. 

Someone should do the same with Fiber Fix.   I think it is like $20 for some of that and it is one time use?  Maybe fiber fix has tested their product in fuel since I spoke with them.  Might be worth a call.