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Discussion Starter · #1 ·
I tried to start my 996 today but no go.
Traced the problem back to the low level fuel sensor
and a broken/ corroded wire.
I am guessing a new unit is required but I am going to ask
this forum " Can this be fixed"?
 

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If it were mine, Id carve out a little of the potting material and solder a new lead onto it and if necessary, repot it with potting epoxy.

t_bare
 
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Bike will start with no level of fuel concerning the gauge :) ecu is utterly stupid here in that sense. i.e it has no idea of the actual fuel level.

That broken thick red wire is the fuel pump positive power feed.
 

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That broken thick red wire is the fuel pump positive power feed.
Yep - no power = no pump = no fuel to injectors and hence no go.

t_bare's suggestion is the cheapest and quickest as long as you can get to the copper conductor to solder.
 

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External pump and filter as per davyj :)

Sorry Rob, I just have an external filter.
Have removed those stupid internal rubber breather hoses and blocked off the spigots though after one fell off and dumped all the fuel over my floor one night..

Best way to do that repair is drill the wire out all the way through, replace it with a new bit and then re-seal with phenol novalac epoxy.
 

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i had to do a 749 one recently. it was easier as i could drill through the old power wire and pull some of the sealant through with the new. don't recall what i used now, could have a look monday.
 

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Not to many sealants work with fuel these days as it's petroleum based mixed with ethanol and whatever catalyst they use to make water mix with oil (used to be acetone, but I can't find any reference to in oil company info these days)
No wonder tanks swell.


I recently tried to seal a fuel tap flange on a Yamaha build I did and every sealant failed over time, Aviation gasket cement, Hylomar, Three bond, Permatex. Loctite flange sealer.
Finally fixed it with low strength Araldite.
Modern fuels are super aggressive.
 

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Discussion Starter · #10 ·
I fixed the fuel level sensor.
Scraped out the phenolic resin around the broken wire, 3mm deep
soldered the connection and then filled the hole with JB weld.
also surrounded all other wires with JB weld.
tested with the battery and a couple of wires. IT WORKS

but and there is always a but.
I noticed the nut that secures the sensor to the pump base was broken.

I ordered on of the Corse Dynamics nuts from Motowheels.


can't complain. I have owned this bike for 19 years so I should expect
the unexpected
 

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i rang the local loctite distributor when i did the 749 one, and they recommended loctite e-pox-e glue. # 1179770 out here.
 

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i rang the local loctite distributor when i did the 749 one, and they recommended loctite e-pox-e glue. # 1179770 out here.



That's the same stuff I used (5 minute Araldite).. it's just an plain epoxy, not Phenol Novalac so time will tell me how fuel resistant it is long term.
I have 6 litres of Novalac here but I thought I'd just try the 5 minute stuff and see how it goes.
I did find a mds for it somewhere and it decreases to about 60% of it's full strength in fuel over quite a short time but as it's just for sealing and not full on retaining I thought it would do the job ok.
 

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Does anyone know where I can find a phenolic epoxy resin in small quantity?

I need to seal my (home built) fuel sensor as well, and at this point I've had 3 different kinds of sealants or epoxies fail over time. I don't want to risk it with another product that is 'maybe' fuel resistant enough, but I'm having no luck finding these EPN resins anywhere in quantities under several gallons
 
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