Fuel Pump
Fuel Pump and Fuel Pump Housing
Some members have complained of backfiring and general poor performance. In this particular case, it was the fuel line pressure regulator. This cause cause fuel pump housing (which is plastic) to crack.
(Sometime later...)
So far so good on my pump housing leak repair. I did about 400 miles over the weekend. There have been many posting questions about the fuel filter/ pump replacement etc... The filter can be removed/cleaned or replaced. The pump is capable of 90 psi and is removable from the housing assembly. The housing assembly is automotive style and that is where my bike developed a problem after my fuel pressure regulator failed...
The small cover just below the tank, on the left side of the bike, hides the pressure regulator and low pressure return line. Pulling the return line and cranking the engine (fuel should spray) will tell you if the system is making enough pressure to open the regulator. If it is not opening, hook a pressure gauge to the high pressure side of the fuel lines and crank the engine again. If the pressure is there, more than 56-57psi, replace the fuel pressure regulator. If you do not have adequate pressure then you must remove the pump assembly from the sub-tank. You can check it for leaks by attaching a low pressure air source to the high pressure fuel outlet and looking for leaks. Mine has several pin hole sized leaks in a small area about the size of a dime.
I cut a piece of 1/32nd sheet metal and gray gasket material (suitable for carburetors and intakes) a little larger than my leak area. I glued the gasket material to the damaged area with Seal All and strapped the sheet metal piece over the site with two 3.5" hose clamps. It is tightened only enough to contour the metal to the curve of the housing. After about 45 mins of dry time for the seal all, I put the bike back together.
Alternate (less expensive) Fuel pump part #
Reference: http://forums.delphiforums.com/n/mb/message.asp?webtag=starroadliner&msg=15236.3
