570 and fuel pump hose issues

Yup, I had the same problem when I installed a new California CycleWorks fuel pump. The hose they provide with the pump is slightly oversized, and because it's FI fuel line it's too stiff for a hose clamp to compress enough to stay on the pump - not even with an FI hose clamp.

I am not certain whether the hose barb on the pump is SAE and the hose they provided was metric, but what solved the problem was Helix Racing Products 5/16 inch inside diameter high pressure fuel line. It comes in three foot lengths, and it's Helix part number 0706-0191 for the clear line.

Also, a standard hose clamp is the wrong kind of clamp. You need a hose clamp that is specifically designed for high pressure fuel injection use. You can readily tell the difference - the correct kind of clamp has a bolt and a nut that tightens a solid band clamp, not the screw type with the band that has angled slits in it that the screw bears against.

Do not be afraid to crank down on the clamp. Tighten it, and then try to pull it off manually with your hands. If it slides on the pump's hose barb, it's not tight enough. Keep tightening until you can't budge it, because if you can make it slide dry then the pump can blow it off wet with the aid of vibration as the motor is running and the bike is under way.

Questions?


BTW, this should be under Fuel.

Ah, an electrical issue. While you have it apart, I recommend you look for frayed/abraded insulation on all the wires that pertain to the fuel pump. Others here have had that problem. Look that fuel pump pigtail over real carefully. I've thought that if it's kinked badly enough it might cause internal breakage of the wires.

Let us know what you find!

If it's not too bad, a soldered and properly insulated repair should do fine. You'll need some small diameter shrink-wrap insulation to do the job right. Provided, of course, that you have some talent with a soldering gun.