Hi all

I have just read Frogs wonderful troubleshooting pages on fuel injection etc and now my head really hurts!

I have had all the major fuel tank issues resulting in a new fuel pump. In-tank it works i.e. spurts fuel.

Q1. If I take the fuel line off at the Injector rail should fuel come out ? OR should it only come out when I hit the start button? It is currently running out slowly?

I am working my way down the line as the tank had the dreaded pump rubber disintegration and some of it may have worked its way into the system.

Next is to remove the rail and see if fuel comes out there. Then take out the injectors and do the same...

Q2. Would it be likely/possible the fuel regulator could be blocked? Or would a new pump push rubber bits through the system?

Thanks for all the help I know I am going to get on this one! This is the best forum ever when you are about to hit your head with a brick...

Mal

Mal, longtime mate! I remember running into you whilst dropping off a girlfriend at the airport in Broome back in 2010 on my Long Ride Round. She's long gone, but I've still got my trusty ol' K100RS.

When you pull off a fuel hose at the rail or remove the rail there will be a significant spray of fuel, not just a dribble. That is unless the fuse for the fuel pump has been pulled prior to switching off a running engine. Since you've replaced the fuel pump this means the system has been depressurised. Is the fuel filter new? Have you cleaned out or replaced the hoses to everything, including the FPR? I'd suspect rubber bits in the internals. Give everything a good hosing out with carbie cleaner and see how you go.

Hi Mal - glad to hear there is a forum member up in Broome as I'm hoping to get up that way before too long. Last year we got as far as Exmouth before my road trip pals decided they wanted more time on the beach and less on the saddle! I have a couple of ex Southern African school mates who have ended up as permanent Broome residents...
In the past when I've had fuel pump damper desolving problems, I haven't bothered about flushing the fpr and it hasn't yet been an issue (to my knowledge). If you want to play it safe, it would make sense to delay reconnection of the fpr to tank fuel bleed off line until you have recommissioning the pump following a tank clean out. This way you could check that your pump is still delivering excess capacity even at wide open throttle condition and you can continue running the fuel bleed off volume into a clear glass container until you are sure that the fpr has been flushed clean of debris.

The fuel filter is on the output from the fuel pump so I don't see how any fuel pump, new or not, could push rubber bits out of the tank to the fuel rail.

If you don't use the correct type of fuel line before and after the fuel filter it can break down. A mate had a problem with cheap fuel line breaking down between the tank and the fuel rail. I couldn't find any rating marks on it. 
Regards Martin.

Very important to use the correct fuel lines. Also, the one for inside the tank has to be suitable to in tank use because it must be resistant to petrol on inside AND the outside, standard fuel line is not resistant to petrol from the outside other than short spillages.

Hello!

Do not use the wrong fuel lines inside the tank !!!
The result is awful, sticky and hard to clean.

Outside the tank use:
Size: inside Ø: 8,0mm outside Ø: 14,0mm  
inside NBR (Perbunan BuhnaN, Butadien-Acrylnitril- Kautschuk), 
outside CR (Neopren)
This is for outside the tank.

Inside the tank you will need:
NBR inside and NBR outside!






NBR is gasoline resistances 


Cheers

I just buy the BMW fuel line for inside of the tank: Part 16121180040

duck wrote:I just buy the BMW fuel line for inside of the tank: Part 16121180040

I also use the BMW lines for inside and outside the tank, simple and no chance of getting it wrong.

Right, as BMW told me that they only have on fuel line.
That is NBR NBR for inside, so good to use outside.

I don't know who told you what but that is the BMW part number for the internal fuel line. It is used in K bikes as well as some R bikes and cars.

http://www.realoem.com/bmw/enUS/partxref?q=16121180040

I've been using it for years in all of my bikes.

Hi all

Well the beast is back on track...

Replaced fuel hoses, filter, fuel pump. Rebuilt injectors, replaced vacuum hose. Checked the valve clearances - they were spot on so no need for shims!

Took a while to get fuel through the system and I was about to give up but she fired up and runns better than ever.

I am trying to balance the butterfly etc but my ebay home made system keeps trying to suck the auto trans fluid up into the system. I am adding baffles of plastic to try and restrict the airflow/vacuum.

Thanks again for all the words of help and encouragement from everyone.

Apparently my BP fuel is the culprit of my woes. I am going to investigate fuel conditioner...

Regards

Mal

I have used the drip irrigation control taps for that purpose. They weren't perfect but did the job and I think something like 20c each.

Fish tank valves are another source of restrictors.
Regards Martin.