fuel pump removal

[109326]

I have a 2002 r1150rs and my fuel gage is'nt working properly.The fuel pump has these hose clips that the repair manual says you need a special tool.Could I just cut them off and use spring hose clips that you buy at a hardware store?

[kbasa]

I have a 2002 r1150rs and my fuel gage is'nt working properly.The fuel pump has these hose clips that the repair manual says you need a special tool.Could I just cut them off and use spring hose clips that you buy at a hardware store?

The factory puts on those little crimp on clips, which I've successfully replaced with hose clamps from NAPA. I usually have a spare floating around the tool kit, just in case.

Pulling the whole pump/arm assembly out through the little hole in the tank is always a treat. It'll only come out one way and only goes back in one way too.

There's a big rubber gasket that seals the whole thing in and you need to do something with the gasket. I can't remember if you need to keep the gasket in gasoline so it doesn't shrink or what. I'm sure someone with better recall than I can help you here. :ha

[BubbaZanetti]

There's a big rubber gasket that seals the whole thing in and you need to do something with the gasket. I can't remember if you need to keep the gasket in gasoline so it doesn't shrink or what. I'm sure someone with better recall than I can help you here. :ha

just buy a new gasket

if you do want to reuse the old gasket you have to let it sit out and dry for a day or two before reassembling.

[MEWAYBRIGHT]

There's a big rubber gasket that seals the whole thing in and you need to do something with the gasket. I can't remember if you need to keep the gasket in gasoline so it doesn't shrink or what. I'm sure someone with better recall than I can help you here. :ha

Fuel usually causes rubber seals to swell thus rendering them usless for anything except the garbage... :nod

[Montana]

You'll have to disconnect the other rubber lines, too, so note which goes where (sometimes there's a little yellow oring as an indicator) and some of those clips aren't crimped and are reusable but they're still special little clips - thanks, BMW.

Don't overtighten the nuts that mount the backing plate on the tank studs, they're soft and will snap off.

[cjack]

And if that's not enough advice, be careful of the green filter sock on the intake to the pump. They cost a lot.

[deilenberger]

just buy a new gasket

if you do want to reuse the old gasket you have to let it sit out and dry for a day or two before reassembling.Keep the old one around for next time you're heading in there - you can rotate them... leave the one you remove to dry out and shrink back to normal size.. I keep a duplicate of all fuel related O-rings in a bag on my workbench.. and just rotate them with the ones "in-service" when I have to open something up.

[deilenberger]

And if that's not enough advice, be careful of the green filter sock on the intake to the pump. They cost a lot.Green? Mine was a lovely shade of tan..

[deilenberger]

You'll have to disconnect the other rubber lines, too, so note which goes where (sometimes there's a little yellow oring as an indicator) and some of those clips aren't crimped and are reusable but they're still special little clips - thanks, BMW.

Don't overtighten the nuts that mount the backing plate on the tank studs, they're soft and will snap off.Tank studs? My '04 has screws..

The clips are sort of a PITA - but can usually be reused, at least once if you're careful opening them up (they only need opening a tiny bit..)

One hint on the two hoses from the top of the tank.. MARK them. Then when you're done and the markings all rubbed or fell off (I tried tie-wraps..) you can easily determine which is which.

One is the rain drain for the filler cap assembly, the other is the vent for the fuel tank.

After reinstalling the tank - assuming you disconnected these hoses down at the frame junction where they go to an in-line connector with the rest of one hose going to the carbon canister, and the other to ground..

Blow through each hose leading up to the tank.

The one for the rain-drain will blow easily, and nothing will return at you. That one goes to the hose going to the ground. The one for the fuel tank vent will blow a bit harder, and when you stop - air should come back out of the hose and smell like gasoline.. you've pressurized the tank a tiny bit by blowing into the hose. That hose goes to the one leading back towards the carbon canister.