I think we all know about the PITA issues with the S2R's crappy wiring. This bug has stolen the life from my baby so I did some research and tested some of the solutions. Fuel pump worked when power was directly contacted, wiring was tested with a volt meter and narrowed it down to you you guessed it, the damn epoxy and soldering join within. After digging into the epoxy and exposing the soldering, I retested the with a volt meter and sure enough power ran from the external clip to the damn fuel pump. Old soldering going was still intact and I was getting 11.5 ohms on the volt meter. Here is where I'm confused and not sure if resoldering the joint and new epoxy is going to cause this issue to re occur. Another concern is the the piece that holds the wiring and epoxy moves, as in pushes in slightly. Should this happen, should there not be a gap around the ring and the metal plate?
Any words of wisdom is appreciated to get her back on the road.
Your terminology is a little confusing.
If you're measuring voltage, you can't read ohms. I guess you're saying you have 11.5 volts at the pump with the epoxy dug out. You should see very little resistance (ohms) from the connector outside the tank to the pump. You should be seeing battery voltage, or very close to it, at the pump. Re-solder the joints, epoxy fill with JB Weld, and ride it.
JB Weld is fuel proof. I've used it on all kinds of plastic tanks on chain saws without an issue.
Sorry, I was just reading off what the volt meter was set to. My biggest concern is why, after the epoxy has been dug out and wiring/soldering exposed, do I have current to the fuel pump?
You most likely moved things enough to restore a connection.
Try this...verify your meter is set to volts. Measure voltage at the battery. Then measure the voltage at the pump. It should be almost identical. If it's more than a tenth of a volt less the solder connections have high resistance...ohms...and need to be resoldered anyway. To prove this check the resistance...ohms...from the pump connector to the pump...make sure the pump is disconnected or you'll fry your meter...it should be very close to zero.
Copy that, thank you!