Aftermarket fuel pump

mp8075 · Apr 28, 2011

BRN2RDE said:
OK, Got it fixed. Again. The non barbed fuel hose connection blew the line off. Looks like the fuel line I got was not the quality it appeared and went a bit soft when the fuel got warm. I replaced that with hopefully better line, and better clamps. So far, so good.

And the inline fuel filter that I added awhile back is a Napa Gold 3027. Very cheap, but has been working very well for 5 months now. If you look at the application for what it fits, you see a couple vermeers with a cummins diesel engine so it is good for a pressurized system.

I'm a bit concerned now. I am getting ready to replace my pump with the ca-cycleworks version. I went to Auto Zone and bought Fuel Injection rated fuel line and clamps, but now I am worried that I will have the same issue as you. Was the original line you bought not FI rated, or did you find some better FI rated line? Let me know, as I was going to do that work to mine tonight.

BRN2RDE · Apr 28, 2011

To be honest, I am worried still about the fuel line. I bought a different brand than what I first put in for the second go around. I am not sure it will be much better. Both were 180psi rated fuel line. I am going to do some checking around to see if I can find some fuel line that is rated for FI and submersion. If I can find it, I will post it up here and take 'er apart yet one more time. By now, I betcha I can have that bike apart and back together in under 40 minutes....

mp8075 · Apr 28, 2011

The line came off of the pump end correct? I am going to look at double clamping it or safety wiring it along with the clamp. I will also look for different line. I'll update if I find anything out.

BRN2RDE · Apr 28, 2011

I found a Gates brand of fuel line that is high pressure, and supposed to be good for submersion in gasoline. I ordered a foot as no shop locally stocks it. Should be in tommorow. Problem is it like $26.00 per foot. Part number # 27093..
Good luck.

mp8075 · Apr 28, 2011

Found the same stuff. $22 a foot at NAPA part #H209. I got it for $18 because the guy quoted me the wholesaler price. I picked up a foot of it. Supposed to be good to 325 degrees F. Won't disintegrate in fuel either. I plan on posting the rest of the pics for this after I get it all done. My tear down pics have already made it to the home page.

mp8075 · May 2, 2011

Here are some pics of my fuel pump change using the ca-cycleworks pump.

Stock pump removed from the tank.
[attachment=2:1hspox7t]2011-04-22 15.44.18 800x600.jpg[/attachment:1hspox7t]

[attachment=1:1hspox7t]2011-04-22 15.45.19 800x600.jpg[/attachment:1hspox7t]

[attachment=0:1hspox7t]2011-04-22 15.48.02 800x600.jpg[/attachment:1hspox7t]

To be continued......

mp8075 · May 2, 2011

fuel pump change continued...

[attachment=2:2gzzq3p3]2011-04-28 18.08.34 800x600.jpg[/attachment:2gzzq3p3]

[attachment=1:2gzzq3p3]2011-04-28 18.13.58 800x600.jpg[/attachment:2gzzq3p3]

[attachment=0:2gzzq3p3]2011-04-30 15.29.11 800x600.jpg[/attachment:2gzzq3p3]

mp8075 · May 2, 2011

fuel pump change continued.....

[attachment=1:338zcwnp]2011-04-30 15.29.00 800x600.jpg[/attachment:338zcwnp]

[attachment=0:338zcwnp]2011-04-30 15.29.38 800x600.jpg[/attachment:338zcwnp]

All in all this wasn't too bad. I had to cut the line between the pump and the filter shorter than I expected. That's the benefit to that flexy line that husaberg used. It can bend when jamming it back inside the tank. I was a bit concerned with the electrical connection on the pump. I ended up massaging the connectors to make them fit tighter and then zip tying the harness to the fuel line right above the connection so they can't come off. I did a short test run behind my house and it seemed to run fine. I hope to get a more thorough test this weekend. Hopefully this puts an end to my fuel pump over heating problem.

Garrison · May 2, 2011

Thanks for the write up and pics. On my first ride on the 390 my bike was showing the overheating and sticking pump symptoms. It would take a couple of minutes to restart each time, but otherwise would run fine. Made some quiries with the dealer, but they're useless. (they recommended that I try the hot start button, which is the cold start to you and me).

I figured I might as well deal with it myself. I ordered the ca pump and gates line. Any particular clamps you're using? I want to make sure whatever I use will work with the unbarbed line.

Thanks everyone.

BigBlueBerg · May 2, 2011

Garrison, Did you try talking to the guys at A&E Racing? They may have some advice!

BBB.

mp8075 · May 3, 2011

Garrison said:
Thanks for the write up and pics. On my first ride on the 390 my bike was showing the overheating and sticking pump symptoms. It would take a couple of minutes to restart each time, but otherwise would run fine. Made some quiries with the dealer, but they're useless. (they recommended that I try the hot start button, which is the cold start to you and me).

I figured I might as well deal with it myself. I ordered the ca pump and gates line. Any particular clamps you're using? I want to make sure whatever I use will work with the unbarbed line.

Thanks everyone.

Nothing special about the clamps I used. I bought a varity pack of clamps from the auto parts store. I first tried a different style of clamp that was a solid metal band, but I couldn't get them tight enough so I went to that more common type of clamp.

Like I said in my earlier post, I don't have any significant time on this yet so I am don't know how my installation is going to hold up. I can't get past thinking that that part of the fuel delivery system is fragile and it has me worried that I made a mistake somewhere that will come back to bite me later. Oh well, time will tell. I hope the new pump solves your problems, and if not, then you have an extra pump.

Garrison · May 3, 2011

BigBlueBerg said:
Garrison, Did you try talking to the guys at A&E Racing? They may have some advice!

BBB.

Hey Blue. My plan was to install the header wrap and tank reflective heat tape to try to bring the temps down a bit and see what the net result is. My fuel was boiling on the first ride we did. I thought maybe in our cooler Canuck temps it wouldn't be so much of an issue for me as it is for the southern US or Australian riders, but it definitely runs hot. We'll see if the wrap and tape does anything.

I'll also look at the stock fuel filter, just in case it's gummed up. I rinsed the tank from new, although from what I hear now maybe I should have used solvent or pressure washing to really clean it out. Plus the dealership would have run it during the initial PDI. Maybe it snorted some tank goo.

If it doesn't work with these efforts I'll put in the other pump. Worst case is I now have a spare pump, so for less than $150 that's a cheap fix. Asking A&E is a good idea, and they might have some insight. But realistically they'd probably be like most shops and say 'bring it in and we'll have a look'. (Which is totally fair of course - they're a business after all!) And I'm not about to waste a day to drive all the way to Brooks and hang around while they work on it. I figure with the steps I'm taking I'll get it sorted - and with the help of all the awesome experts on this site! Thanks for the tip. Have you been out on yours yet?

dakota_c69 · May 3, 2011

Garrison said:
... On my first ride on the 390 ...

Hey Garrison,

I was just wondering where did you go riding?

I was out to a gravel pit a couple of times since I got the bike and had no heat issues at all. The fan didn't even come on. Have you considered ceramic coating the pipe?? S'posed to be better than the the wrap and no maintenance .

BBB.

Garrison · May 3, 2011

Ceramic coating is a good idea. Maybe I'll do that in the offseason, or sooner if I can find someone locally who can do a quick turnaround.

We trailered to the Lake Kookanusa area a week ago. It was awesome riding - pretty warm out and dry and dusty conditions. It's my new favorite riding area. I think we'll be going there again on the 15th.

My fan only came on a couple of times, and only for a few seconds. I still boiled the fuel though.

69candy · May 4, 2011

R u guys sure its the fuel boiling?? Reason I ask is I was riding on the weekend and there was another berg with me, 09 570 mine is a 2010 570. Both bikes boiled at the same time and we switched them of to let them cool down, 1st gear in tight trees tring to make a track. When I got my helmet of I could hear the bubbling and thought, theres a first, I have boiled my fuel as well. Upon inspection it was the coolant boiling in the rad but not comming out the overflow. I was sure it was the fuel but it wasn't. and when you think about it, if fuel was boiling and bubbleing, I for one would not like to be around it with those fumes!!! You may well be doing it, I don't know, but takes a fair bit of heat to boil, I would think that if it was that hot, the tank would melt. How do I know? When my bike was on fire in the shed with the tank melting and on fire, the fuel was not boiling, it was just leaking out from around where the tank was melting away and fueling the fire.
Food for thought??

Garrison · May 4, 2011

Thanks for the input. I'll definitely give it a closer look next ride.

My hunch is that it was the fuel though. I bought my bike in January, and dumped the coolant to install my rad guards. Knowing that it would be sitting in a freezing garage, I added 50/50 coolant and distilled water. If I recall, that raises the boiling point another 20 degrees or so. It's certainly still possible that it was boiling coolant, but I only heard the fan come on a couple of times and only for a few seconds, so I assumed the coolant wasn't overly hot. Definitely food for thought though. I'll look into it next ride.

I don't know if header wrap and tank reflective tape will have any affect on my starting-when-hot issues. Couldn't hurt I guess. If it still has issues I'll swap out the pump. Tracking numbers indicate it should be showing up today.

mp8075 · May 4, 2011

Last summer while riding at Taylor Lake I also thought my fuel was boiling. I could hear the percolating sound. Upon further inspection it was the coolant in the lower line. I put a screw driver up to the line and then put my ear to the end of the screw driver. I could both feel and hear the coolant bubbling inside the line. I have no tank liner or header wrap on mine, although I do have a fan, and have had it very warm, but have yet to have the fuel boil.

Garrison · May 4, 2011

Good advice. Thanks! I just did some reading on coolant, and it sounds like I need to go to straight water or water + Water Wetter. I can lower my temps that way, from what I gather.

Sorry to hijack this away from fuel pump issues! I'll shut up now. At least until I try my new pump.

mp8075 · May 9, 2011

I was able to do a decent test ride yesterday. New ca-cycle fuel pump seems to be working just fine under normal conditions. It wasn't hot enough to see if the over heating issue is gone. I have a race in a couple weeks which will be a thorough test.

69candy · May 10, 2011

Good news. Keep us in the loop

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