Cracked fuel pump housing fix

[CHROMINATOR]

By far the best write-up I have seen here, hopefully I will never have to use it but it's great to know it's available if needed.

[RoadStarRaider]

[A.T.]

I'm pretty sure this Fuel Pump is used in other Yamaha applications - as in marine applications. 

Marc  - may want to consider a copyright or patent on this process - it's your hard work.

[wolfraider]

Very nicely done! That should be very helpful to anybody trying to have a more permanent fix!

Too bad I didn't get it done before you replaced your housing though.

No problem, as I had one laying around!!! 

[Zxdave]

Excellent write up Brother ! You are a big asset to all of us here no doubt !

[CHROMINATOR]

Excellent write up Brother ! You are a big asset to all of us here no doubt !

  

[eakrob]

This write up looks like it was put together by a college professor. Dang!

[the urban legend]

This write up looks like it was put together by a college professor. Dang!

Auto mechanic actually. Thank you for the compliment.

[Deyv]

Very, Very good document.  The time you took shows in the level of detail and clarity documented. 

2 questions, first, what is the approximate cost of the parts and materials involved?  and second, how long would you estimate this repair to take?

I really liked the use of the ECU programming for draining the tank, When I did it, I used (if I remember correctly used some jumper wires) to manually drain the sub tank.  Found out how on what was basically the only Youtube video with a decent showing of how to remove the pump.

[the urban legend]

Very, Very good document.  The time you took shows in the level of detail and clarity documented. 

2 questions, first, what is the approximate cost of the parts and materials involved?  and second, how long would you estimate this repair to take?

I really liked the use of the ECU programming for draining the tank, When I did it, I used (if I remember correctly used some jumper wires) to manually drain the sub tank.  Found out how on what was basically the only Youtube video with a decent showing of how to remove the pump.

Draining the tank by using jumper wires can cause sparks, and that can get very dangerous when dealing with fuel. That's why I prefer my method. And it works really well.

Cost> I did this just over 2 years ago. At the time IIRC I was well under the $200 mark (Canadian). Going with a 10 micron serviceable filter like I wanted would increase the cost.
Time> There was a lot of thinking up methods that wouldn't work before I got to the solution that I shared with everybody. It took me a while to do it, but now that I know where I'm going I figure it's an afternoon job. Cutting/shaping is the longest part. Everything else is pretty straightforward disassembly/reassembly.

[NMRaider]

Great Write up!

I wish I had seen this as I just recently replaced my fuel pump.

C

[the urban legend]

I just realized that I posted this in the wrong section. I meant to post in the "How-to" section, but I don't think I can move it now.

Could one of the admins move the topic please? Unless you think it belongs here in the "General Raider Discussion" section.

[the urban legend]

A little update on this.

It's been almost 3 full riding seasons for me, and just over 10k miles since I modified the fuel pump housing. I've been keeping an eye on fuel pressure by taking pressure readings 2-3 times a year and comparing that to the reading I had with the good housing before the mod. I'm happy to report that the pressure hasn't dropped at all from the original reading.

Note > All readings were done using the same gauge. And yes, I think the gauge is off a little on the high side.