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Old 19th July 2019
smm1200 smm1200 is offline
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Sportster/Buell Model: 1200xl
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Default In tank pump and filter work

Just finished assembling the in tank pump module. I have to credit the foreigners with small fingers that do this job. Couple things to warn others of that are not mentioned in the manual or UTubes that I reviewed. First and most important is a small clip not shown in manual that holds the ground clip onto the press reg. BE SURE to look at this clip install before just pulling the regulator out of the housing. I THINK it fits with wide side into the housing channel over the wire end, and then press down so that the small side is against the press reg body.....but use this for my opinion only....check before remove....I did not see it live or in manual beforehand. Second, since my hose was brown and stiff, I got a new filter house with hose. Again, no mention that the hose end must be heated to go over the fitting on pump. I used a small butane torch. Care to ensure you only see some greasy film on plastic, no more heat, and have the tube over the fitting ready to push on. AND, have mechanics glove, I did not, and was burning the fingers the whole way. Note, I am getting older and less astute. Last interesting problem was that the size 50 clamp for the pump was too large and barely snugged down. Probably better to try to find a very narrow small normal type hose clamp for this job and keep the nut out of the way for install. Had I known that getting all the parts and the difficulty level was so, I might just order the assy next time. I think that just changing the filter would be OK, but if you need to disassy the pump for the screen sock, you will have to deal with the clamp deal. Chinese puzzle that I dont like. I have worked on bikes since my first in 68, and I dont like this complication....rather be ridin. My buell cyclone had no pump, a simple carb, and after some tweaking was absolutely wild for power and accel off idle. BTW, the hose clamp is a 12.3.
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Old 20th July 2019
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harley506d harley506d is offline
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Default

Sounds like one of those nightmare jobs.
I only ever use boiling water to soften hoses, just dip the end in and wipe off any excess before fitting.
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Old 20th July 2019
smm1200 smm1200 is offline
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Default

That is a great idea that I may have to use. Original pressure was running at 60, and with new pump and original regulator, only 40 psi. Not sure whether all the air has been purged, but am suspecting it may have to come back out. What fun. Thanks for the hot water technique.
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Old 22nd July 2019
smm1200 smm1200 is offline
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Default

Ordered another hose hopefully will not kink. Will try that first but will not affect low pressure. Will ride to test first. Also ordered another pressure regulator. I THINK that the pump runs constantly with engine running, and pressure regulator just spews out excess to maintain pressure. Can hear overflow inside tank with engine running. So, believe pressure totally regulated by the mechanical device. Will replace him next and also check for any leaks in system with it out of tank using air on pump. See what happens in this daytime nitemare. Good riding weather.
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