Let's go back two winters ago to when I was servicing the '02 S4 for my first time. I did the valves, belts, base/head gasket and all that jazz. Amidst all that work, I was going to replace the fuel filter but was unable to extract 2 of the set screws around the ring on the top of the tank. The heads stripped out... go figure. I put it on the back burner to focus on getting the rest of the bike sorted and haven't done any work to it since.
Fast forward to tuesday morning. I'm on my way to work at 4:45 AM and the bike cuts out. I wheeled it into a parking lot and said a few words.
Turn the key and the dash sweeps. I hear the fuel pump whir. Thumb the starter and it kicks to life for a few short seconds and then chokes out quickly. If I try to start it again, it doesn't turn over. If I let it sit for a minute, thumb the starter and it kicks to life for a few seconds and dies out again.
Anybody else get the feeling that the fuel filter needs replaced? 20K on the bike and not sure when/if it was ever replaced.
The filter plugged or internal lines perforated/degraded would be my first targets.
But I'm a bit bothered about it not cranking.
Did it always prime the fuel pump during this episode?
Sorry Nick. I was in a bit of a rush when I wrote that.
It does continue to crank. It just doesn't turn over after the first try unless I let it sit for a minute.
No worries.
I think you're going to have to get inside the tank, if not to fix, at least to eliminate suspects...
Ok. I'm going to try to extract the set screws that are stuck.
You see any reason why they couldn't be drilled out and tapped for a larger diameter.
Quote from: lazylightnin717 on July 20, 2013, 06:31:19 AM
Ok. I'm going to try and extract the set screws that are stuck.
You see any reason why they couldn't be drilled out and tapped for a larger diameter.
Just leave them out.
The 6 remaining will do a perfectly good job of securing the cap holder.
When I coat tanks I use an old bung to seal the opening and I only use 2...works fine.
All of the set screws need to be removed to get the ring out though?
Quote from: lazylightnin717 on July 20, 2013, 07:48:54 AM
All of the set screws need to be removed to get the ring out though?
Yes
Quote from: lazylightnin717 on July 20, 2013, 07:48:54 AM
All of the set screws need to be removed to get the ring out though?
Try a Torx small enough to tap into the boogered grub screws, if that doesn't work a left hand drill bit might spin them right out.
I tried the torx bit and other extraction methods. Nothing worked so I drilled them out.
I pulled the ring out with some persuasion.
Wish I could see in the fuel filter but it really doesn't matter because it is getting replaced anyways.
Oh and when I pulled the filter out, the other end was not connected to the pump... :P
OTOH, does anybody know a good source for submersible fuel line. None of the mainstream auto parts stores carry it. I'm going to try some of the marine stores around the area but other than that, I got nothing.
NAPA auto parts stores have it, or can get it.
The last time I got some, it was ~$30 for a 1 foot piece.
IIRC, you'll need two.
The spec is 30R10.
The only manufacturer I found was Gates.
30R9 hose is fuel injection rated, but not submersible.
Pretty sure the NAPA# is H 209.
Looks like there are 2 different sizes.
Larger ones for the pump/filter assembly and smaller diameter for the overflow.
$30 a foot seems outrageous >:(
Quote from: lazylightnin717 on July 20, 2013, 06:30:11 PM
Looks like there are 2 different sizes.
Larger ones for the pump/filter assembly and smaller diameter for the overflow.
$30 a foot seems outrageous >:(
You won't find submersible hose for the smaller 1/4" diameter...at least I haven't.
It's not under pressure. I use standard 1/4" fuel line.
Good luck finding it cheaper.
http://www.amazon.com/s/?ie=UTF8&keywords=submersible+fuel+line&tag=googhydr-20&index=automotive&hvadid=17937520101&hvpos=1t1&hvexid=&hvnetw=g&hvrand=6419230662129505824&hvpone=&hvptwo=&hvqmt=e&hvdev=c&ref=pd_sl_8h9447sa9_e (http://www.amazon.com/s/?ie=UTF8&keywords=submersible+fuel+line&tag=googhydr-20&index=automotive&hvadid=17937520101&hvpos=1t1&hvexid=&hvnetw=g&hvrand=6419230662129505824&hvpone=&hvptwo=&hvqmt=e&hvdev=c&ref=pd_sl_8h9447sa9_e)
Anything I should do with the electrical connection to the fuel pump while I am in there? It seems awfully exposed..
Waiting for a new o-ring from Feracci for the tank flange. The one I got from DT several months ago ended up being too big [bang]
Any tricks to getting that back on without pinching it?
They seem to work fine as is.
Grease the o-ring. it's next to impossible to install the flange otherwise.
What am I not understanding about this?
Is the o-ring not supposed to sit in the groove?
(http://i784.photobucket.com/albums/yy130/rappevan/null_zps29a55e05.jpg) (http://s784.photobucket.com/user/rappevan/media/null_zps29a55e05.jpg.html)
(http://i784.photobucket.com/albums/yy130/rappevan/null_zpsd66487e4.jpg) (http://s784.photobucket.com/user/rappevan/media/null_zpsd66487e4.jpg.html)
Wrong O-ring.
2nd time around..
Can you anybody confirm the part # of the correct o-ring?
Is it possible that I have a different tank and need a different size o-ring than the normal S4?
:edit: looks like McMaster carries several different sizes. I would be willing to go that route too.
I'm coming up with 886.4.011.1A O-Ring
What's wrong with the old one?
Yes, 88640111A is the O-ring for all steel Monster FI tanks.
That looks like the O-ring for the fuel pump flange on a 916 or the like.
I'd go with this one:
http://ca-cycleworks.com/products/maintenance/gaskets-o-rings/or-40111a (http://ca-cycleworks.com/products/maintenance/gaskets-o-rings/or-40111a)
There's a pic showing how it fits.
That's the part number that I came up with and the same one Ferracci pulled.
I cross referenced and all of the steel tank Monsters use the same o-ring.
Me thinks they screwed the pooch on this one.
They asked me to send them pictures and told me they would call me back. I never got a call back.
Quote from: Speeddog on July 26, 2013, 08:28:52 AM
Yes, 88640111A is the O-ring for all steel Monster FI tanks.
That looks like the O-ring for the fuel pump flange on a 916 or the like.
I'd go with this one:
http://ca-cycleworks.com/products/maintenance/gaskets-o-rings/or-40111a (http://ca-cycleworks.com/products/maintenance/gaskets-o-rings/or-40111a)
There's a pic showing how it fits.
That's definitely the one I need. What a dumb hold-up this is [roll]
What's wrong with the old one?
It was old :P
Quote from: lazylightnin717 on July 26, 2013, 05:04:51 PM
It was old :P
Allow me to be crude...
If it fits the cap holder...
use the make the beast with two backsing thing.
Clean it off...reinstall it, grease i,t and use it. ;D
[laugh]
I forgot to mention that I threw the old one away...and I'm not goin' dumpster diving in NJ.
Needless to say, I ordered a 5 pack of Viton o-rings from McMaster for $8 and it worked like a charm. Bike fired right up and everything looks to be good for now.
I might go back in with new fuel line for the overflow. They look a little funky in there