Fueling issue?

[lazylightnin717]

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.

[Speeddog]

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?

[lazylightnin717]

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.

[Speeddog]

No worries.

I think you're going to have to get inside the tank, if not to fix, at least to eliminate suspects...

[lazylightnin717]

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.

[ducpainter]

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.

[lazylightnin717]

All of the set screws need to be removed to get the ring out though?

[ducpainter]

All of the set screws need to be removed to get the ring out though?

Yes

[Ddan]

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.

[lazylightnin717]

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... 

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.

[Speeddog]

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.

[ducpainter]

Pretty sure the NAPA# is H 209.

[lazylightnin717]

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 

[ducpainter]

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.

[Ddan]

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