Are you trying to remove the pump with the tank upside down because the float can get stuck in the narrow sides of the tank. I removed mine with the tank upside down (so the float is highest and the arm straightest), then rotated the pump about 90 degrees clockwise so the float arm was effectively pointing at the front of the tank. The nylon clips that hold the float arm to the sender unit are fairly flimsy too. Also the float stop/rest is really very feeble - if that snaps the float will drop much lower and get stuck.

I've got the tank stood on its front end, but I'm sure it's not the arm that's causing the problem, but the stop itself.

Trouble is, that begs the question "how on earth did Yamaha put it together in the first place?"

Can't really suggest anything else really! I got might out, so I can't believe it should be any different?? I suppose its a bit like moving an old sofa out of your living room through a doorway - you know it went in, so it must come out, but you spend hours trying, swearing and kicking things, then the wife comes along, moves it an inch one way and it slips out with ease! My suggestion would be to let someone else have a go, probably someone female...

IT'S ALIVE!

Got the pump out in the end with a bit more wiggling and some *very* gentle bending of the float arm stop with a screwdriver.

I was pretty sure beforehand that the problem was a leak somewhere in the pump assembly. Reasons:

- Since Kev had said the system should be self-priming, then the only other option I could think of was the pump failing to deliver enough fuel to the fuel rail. I could hear the pump working when I turned the key, which suggested it was producing some flow, but that wasn't reaching the injector.

- When I took the tank off, fuel came out of the pump outlet. It wasn't until I started to suspect a problem that I thought to check whether this was supposed to happen (I'd just treated it as annoying before). Turns out the answer is 'no'. More evidence for a leak between pump and outlet.

This was confirmed with the pump out by the fact I could blow in the outlet, and hear air escaping somewhere.

The pump assembly has two main parts, the pump unit itself, and the tank interface/mounting flange. These are both plastic and are just a snap fit together. The output from the pump has to flow from one to the other, and where it does, it is sealed with an O-ring.

When I dropped the tank, it dislodged the pump unit slightly. I actually found this out at the time, clipped them back together without removing the whole pump from the tank, and thought no more about it until today.

With the pump out, I separated the two parts, and found that the drop had also displaced the O-ring, such that it wasn't sealing. When I put it back together properly, and tried again to blow into the outlet, it wasn't possible.

Pump back in tank, tank back on, fuel in, thumbed the button, and it fired within a second or two and settled down into a stable idle.

:thumbsup[1]:


Moral of the story kids:

Don't drop your fuel tank. This particular episode of clumsiness has cost me...

- �63 ish for a new fuel hose
- �80 ish for a complete XTX throttle body from eBay (same fuel rail, so a better option than paying ~�220 for just the fuel rail from Yamaha)
- Two weeks of having to commute in the pickup, which uses over twice as much fuel and wastes at least half an hour a day in traffic.
- Going to the Dragon Rally, by a matter of a few hours. I could technically still go, but even if I left right now (which I can't, because I'd need to finish putting the bike together, not to mention packing) I still wouldn't quite make it there before dark.


On the bright side, I've not had to spend the truly ridiculous �715 :107: that Yamaha want for a new fuel pump.



Thanks to all who have contributed ideas to this thread (and GULGo and tripletom for helping out via PM and phone respectively)

Nice one - a happy ending!

Having a laugh - �715 for a fuel pump!?:smilielol:

Nice work mate.

i had that prob when I put the gilimoto tank on...
that little bit that catchs..push it down it will unclip from the pump
unplug the wires..drop it in the tank..remove the pump..then retreive the
bit in the tank... clip it back on the pump & wires... pump fits in with it on..
Well it did in the Gilimoto tank..

Nice one mate, pleased it's all sorted.