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Discussion Starter #1
The bike sat a couple years without running or having winterized/stabilized the fuel. Took the tank off today and wondering if it can be cleaned and repaired with a new cap and pump assembly? The fuel pump assembly looks like it's trashed and the lines in the tank basically melted.

The lines into the bike didn't look as foul, is there a way I can check if any of this fuel got into the bike?

Gallery: https://imgur.com/a/PZnYG

How do I clean this tank out for a new pump/cap?
 

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That's rough. Looks like some water intrusion as well, possibly due to the alcohol mix gas.

I would say you can assume the outside the tank lines and the throttle bodies / injectors aren't much better. There is fuel in the loop unless you take steps to drain it, which I doubt was done here.

How to clean it? I'd strip the fuel pump flange and replace lines, pump and filter. While it's stripped, maybe some carb or brake spray cleaner and brushes. Tank? Probably slosh some fresh gas or other solvent around. Maybe just a rag wet with solvent that you could use to wipe what you can reach. You can get in there pretty well through the pump flange hole.

If it were my bike, I'd plan on replacing the lines to the throttle bodies too. Pull the injectors for clean, inspect hopefully not replace. Spray some carb cleaner through the fuel passages in the throttle bodies to flush them out.

Pump. This is the correct Bosch OEM pump Ducati uses and charges many times more than this for the special box, I guess.
https://www.amazon.com/dp/B000BZICV8?tag=vs-powersports-convert-amazon-20

Filter. Again the same filter from Ducati is around $45.
https://www.amazon.com/gp/product/B005GDJSXQ/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

Submersible line. Sold in 1 Ft lengths
https://www.amazon.com/gp/product/B0049BIGB6/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Proper fuel hose clamps
https://www.amazon.com/gp/product/B002AV7AXC/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

Edit: You need an o ring too. I used to get those on Amazon, but the seller doesn't have them any more. The PN and size is M83248/1-247 (4-5/8 ID X 4-7/8 OD X 1/8 W) Viton 75A. Should be a Dollar or two anywhere you can get them. Ducati likes to have $16.00 for one!
 

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Discussion Starter #3
That's rough. Looks like some water intrusion as well, possibly due to the alcohol mix gas.

I would say you can assume the outside the tank lines and the throttle bodies / injectors aren't much better. There is fuel in the loop unless you take steps to drain it, which I doubt was done here.

How to clean it? I'd strip the fuel pump flange and replace lines, pump and filter. While it's stripped, maybe some carb or brake spray cleaner and brushes. Tank? Probably slosh some fresh gas or other solvent around. Maybe just a rag wet with solvent that you could use to wipe what you can reach. You can get in there pretty well through the pump flange hole.

If it were my bike, I'd plan on replacing the lines to the throttle bodies too. Pull the injectors for clean, inspect hopefully not replace. Spray some carb cleaner through the fuel passages in the throttle bodies to flush them out.

Pump. This is the correct Bosch OEM pump Ducati uses and charges many times more than this for the special box, I guess.
https://www.amazon.com/dp/B000BZICV8?tag=vs-powersports-convert-amazon-20

Filter. Again the same filter from Ducati is around $45.
https://www.amazon.com/gp/product/B005GDJSXQ/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

Submersible line. Sold in 1 Ft lengths
https://www.amazon.com/gp/product/B0049BIGB6/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Proper fuel hose clamps
https://www.amazon.com/gp/product/B002AV7AXC/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

Edit: You need an o ring too. I used to get those on Amazon, but the seller doesn't have them any more. The PN and size is M83248/1-247 (4-5/8 ID X 4-7/8 OD X 1/8 W) Viton 75A. Should be a Dollar or two anywhere you can get them. Ducati likes to have $16.00 for one!
Thank you, really thanks for being so thorough. I have an o-ring fortunately and a pump but it was a cheap one off ebay so I'll get the Bosch. I'll strip the pump flange and clean it. If I'm replacing the lines to the throttle bodies, those are the two fuel lines that attach via QD under the tank labeled "in" and "out?"
 

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If I'm replacing the lines to the throttle bodies, those are the two fuel lines that attach via QD under the tank labeled "in" and "out?"
Yes. You can get any good quality 5/16" fuel injection rated hose for that. No need for the submersible stuff. Two lines to the tank and that short line between the injectors. Ducati uses those nice crimp type clamps on these lines. You can get that stuff pretty easy, but those breeze clamps are fine here too. Just don't use the common worm gear hose clamps you can get at hardware or auto parts stores. They don't clamp evenly all the way around.
 

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Just a heads up about fuel hose.

Since 2009 I've used ordinary external automotive fuel injection hose in the tank which seems capable of lasting 5 or six years easily and can be swapped out at filter change times and is very inexpensive.

Recently I swapped the lines out with the "correct" Gates submersible fuel line hose and twelve hours later I woke up smelling petrol in the house.
This "correct" fuel line hose had softened, almost melted and popped off the tank breather spigot on the pump base plate and allowed the full contents of the tank to drain down the hose under the bike onto my floor.

I replaced the hose (after very thoroughly cleaning and ventilating the house) with "ordinary" fuel injection hose and had no problems since.

It would appear that as with anything that is expensive, someone out there is manufacturing a cheap very poor quality knock off imitation and selling it to unsuspecting dealers and agents.
I bought mine from a highly respected commercial supplier not ebay so it was a complete shock to have this happen.
Before using the "ordinary" hose I coiled it up in a glass jar full of fuel and let it sit for 24 hours before using it just to be sure.

As I said... just a heads up... it's a tricky world we live in these days and probably a good job I don't smoke too :)

This incident scared me to the point I deleted the internal breather hoses and plugged the base flange drain holes as well as the two holes in the fuel tank recess, simply allowing the tank to vent to atmosphere via the cap as on a normal older bike so I'll never have to worry about this again.
 

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I’ve done this 5 or 6 times.

Anything rusted soak in vinegar. You got lucky the tank is lined, otherwise it would need a good soak. Make sure the lining isn’t bubbling or has holes anywhere. Take everything off the flange and soak that for 24 hours.

You should only need to replace the gas lines that are submerged in the tank. Make sure the new lines you buy are rated as submersible hoses.

New pump, new filter, new flange O ring and you will be good to go.
 

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That's rough....

If it were my bike, I'd plan on replacing the lines to the throttle bodies too. Pull the injectors for clean, inspect hopefully not replace. Spray some carb cleaner through the fuel passages in the throttle bodies to flush them out.
I'd also suspect the fuel pressure regulator may be clogged with gunk. Any thoughts on this from the experienced wrenches here?
 

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Discussion Starter #8
I’ve done this 5 or 6 times.

Anything rusted soak in vinegar. You got lucky the tank is lined, otherwise it would need a good soak. Make sure the lining isn’t bubbling or has holes anywhere. Take everything off the flange and soak that for 24 hours.

You should only need to replace the gas lines that are submerged in the tank. Make sure the new lines you buy are rated as submersible hoses.

New pump, new filter, new flange O ring and you will be good to go.
So the stock filter was trashed obviously, the filter that came with the pump (not the Bosch I ordered but an ebay pump) doesn't look anything like it, considering the filter fits so neatly into the flange, does the Bosch have the right filter?

https://imgur.com/a/pMuPB

Also, any clue why one of my intakes is so much dirtier?

Flange is stripped and soaking in vinegar.
 

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Just a heads up about fuel hose.

Recently I swapped the lines out with the "correct" Gates submersible fuel line hose and twelve hours later I woke up smelling petrol in the house.

This "correct" fuel line hose had softened, almost melted and popped off the tank breather spigot on the pump base plate and allowed the full contents of the tank to drain down the hose under the bike onto my floor.
Yeah, I wouldn't use that stuff. I did my research and found that the only truly stable submersible fuel line is made of a material called Tygon. It's available commercially over the web, as well as on Amazon.

I got my supply from the manufacturer for about $2 a foot.
https://www.usplastic.com/catalog/item.aspx?itemid=105478&catid=864
spec sheet here:
https://www.usplastic.com/catalog/files/specsheets/57728 4215.pdf

I used this on my Mille R when I converted over to a steel tank from the plastic rotomolded Acerbis OEM tank. After seeing the condition of the Gates tubing inside that tank, I wasn't about to use it on the conversion.

I installed the tank, with the Tygon hose for the submerged, in tank lines about 3 years ago and have not had issues since. In fact, I use the Tygon hose any time I need fuel hose. It doesn't harden up, it's UV resistant and is submersible so I see no reason to use any other product.

Also, use stainless fuel injection hose clamps. The ones without the exposed serrations for the worm drive screw. Available on Amazon for low $$.....sean
 

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So the stock filter was trashed obviously, the filter that came with the pump (not the Bosch I ordered but an ebay pump) doesn't look anything like it, considering the filter fits so neatly into the flange, does the Bosch have the right filter?

https://imgur.com/a/pMuPB

Also, any clue why one of my intakes is so much dirtier?

Flange is stripped and soaking in vinegar.

I just throw away the filter that comes with the pump. With those chinese pumps I re-use the OEM one or don't use one.

You will need one of these
https://www.amazon.com/gp/product/B005GDJSXQ/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1
 

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Discussion Starter #12
So I now have the fuel pump assembly finished with the new hoses, filter, screen and pump.

But now the fuel tank needs attention. There was rust inside and the lining got rust under it and it has flaked off in large areas inside the tank. How do I go about fixing this problem so I can reassemble everything and ride? Is there a strong solvent I can clean it with or does it need to be professionally cleaned and sealed?
 

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That's a tough deal. New tank maybe? I dunno.

I did my old oil boiler tank years ago as it had a pin hole and some rust. I took it to a radiator shop and had them clean and seal it for me.

Worked great. I never had to deal with any of the details, just installed, gassed up and rode.

Never leaked a drop either.....and that was.....20 years ago maybe......1997 so 21 years ago.

I'd start with a reputable radiator repair shop (a disappearing establishment these days) and see what they can do with it.

Due to the rust under sealer, it will probably require them to hot tank it if they still do such things.

IF so, that would most likely require a repaint as the hot tank is going to strip it down to bare metal so it can be sealed.

I dunno for sure though, as I've never had to have it done to a tank. I know it strips off all the paint on a radiator so I would assume the same on a tank.

There is the possibility of doing using some DIY electolysis but I don't know how much work that would be.

I've read some stuff where you can hook up a battery and use a sacrificial anode to remove rust...but that wasn't trapped under a layer of sealer.

Hence my recommend to try a radiator shop if you can still find an old school one. And one that still uses a hot tank. The new tank idea still might be easier..........sean
 

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That's rough. Looks like some water intrusion as well, possibly due to the alcohol mix gas.

I would say you can assume the outside the tank lines and the throttle bodies / injectors aren't much better. There is fuel in the loop unless you take steps to drain it, which I doubt was done here.

How to clean it? I'd strip the fuel pump flange and replace lines, pump and filter. While it's stripped, maybe some carb or brake spray cleaner and brushes. Tank? Probably slosh some fresh gas or other solvent around. Maybe just a rag wet with solvent that you could use to wipe what you can reach. You can get in there pretty well through the pump flange hole.

If it were my bike, I'd plan on replacing the lines to the throttle bodies too. Pull the injectors for clean, inspect hopefully not replace. Spray some carb cleaner through the fuel passages in the throttle bodies to flush them out.

Pump. This is the correct Bosch OEM pump Ducati uses and charges many times more than this for the special box, I guess.
https://www.amazon.com/dp/B000BZICV8?tag=vs-powersports-convert-amazon-20

Filter. Again the same filter from Ducati is around $45.
https://www.amazon.com/gp/product/B005GDJSXQ/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

Submersible line. Sold in 1 Ft lengths
https://www.amazon.com/gp/product/B0049BIGB6/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Proper fuel hose clamps
https://www.amazon.com/gp/product/B002AV7AXC/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

Edit: You need an o ring too. I used to get those on Amazon, but the seller doesn't have them any more. The PN and size is M83248/1-247 (4-5/8 ID X 4-7/8 OD X 1/8 W) Viton 75A. Should be a Dollar or two anywhere you can get them. Ducati likes to have $16.00 for one!
Seriously... thanks for being so thorough Dan. This is one of those posts that should be a sticky somewhere, perhaps in the hall of wisdom.
 

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The filter cup is available separately from the pump from the dealer for $13.00 +/- and fits the ebay pump.

I have also bought the cheapie $15 pump from ebay with the same filter style that could not be used. The pump works fine for more than 2 years now.




So the stock filter was trashed obviously, the filter that came with the pump (not the Bosch I ordered but an ebay pump) doesn't look anything like it, considering the filter fits so neatly into the flange, does the Bosch have the right filter?

https://imgur.com/a/pMuPB

Also, any clue why one of my intakes is so much dirtier?

Flange is stripped and soaking in vinegar.
 

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That's rough. Looks like some water intrusion as well, possibly due to the alcohol mix gas.

I would say you can assume the outside the tank lines and the throttle bodies / injectors aren't much better. There is fuel in the loop unless you take steps to drain it, which I doubt was done here.

How to clean it? I'd strip the fuel pump flange and replace lines, pump and filter. While it's stripped, maybe some carb or brake spray cleaner and brushes. Tank? Probably slosh some fresh gas or other solvent around. Maybe just a rag wet with solvent that you could use to wipe what you can reach. You can get in there pretty well through the pump flange hole.

If it were my bike, I'd plan on replacing the lines to the throttle bodies too. Pull the injectors for clean, inspect hopefully not replace. Spray some carb cleaner through the fuel passages in the throttle bodies to flush them out.

Pump. This is the correct Bosch OEM pump Ducati uses and charges many times more than this for the special box, I guess.
https://www.amazon.com/dp/B000BZICV8?tag=vs-powersports-convert-amazon-20

Filter. Again the same filter from Ducati is around $45.
https://www.amazon.com/gp/product/B005GDJSXQ/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

Submersible line. Sold in 1 Ft lengths
https://www.amazon.com/gp/product/B0049BIGB6/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Proper fuel hose clamps
https://www.amazon.com/gp/product/B002AV7AXC/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

Edit: You need an o ring too. I used to get those on Amazon, but the seller doesn't have them any more. The PN and size is M83248/1-247 (4-5/8 ID X 4-7/8 OD X 1/8 W) Viton 75A. Should be a Dollar or two anywhere you can get them. Ducati likes to have $16.00 for one!
I don't mean to hijack the thread. But would that fuel pump work for an 03 999? I'm going to replace the fuel filter too but the bike has been sitting for 6 months now with no stabilizer in the gas so I wanted to change the pump as well. If that pump doesnt work, how would I find out the bosch part number for it? I don't want to pay a few hundred for a fuel pump lol.
 

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Just wanted to chime in on the clamps. I did this repair on an RSVR....didn't listen and the in tank hoses poped off. You need the proper clamps, and they need to be proper tight, dont be scared. I became an expert in RSVR Tank and Fuel Pump Extraction Techniques against my will due to being stupid and then being scared "nooo that's WAY to tight" and the hose poped off on the first ride...
 

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I don't mean to hijack the thread. But would that fuel pump work for an 03 999? I'm going to replace the fuel filter too but the bike has been sitting for 6 months now with no stabilizer in the gas so I wanted to change the pump as well. If that pump doesnt work, how would I find out the bosch part number for it? I don't want to pay a few hundred for a fuel pump lol.
I don't believe so. The 999, and that generation of Ducati in general, uses a different pump. The one I listed is for 916 series, ST series and maybe some early fuel injected Monsters. The best way to get the Bosch number is to physically look at the pump you're replacing. My OEM Ducati pumps had the Bosch PN clearly on it. Very likely someone has already figured it out, however, and a Google search will find it...
 

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Fill gas tank up with vinegar, let is soak for 24-48 hours. Put some coins or metal chain in there to loosen the rust and it will look brand new.

Rust will come off with an acid. Some people use stronger acids like phosphoric. There are also treatments that will redeposit metals.

Or you can line it with POR15 or something.


But vinegar should be all you need. I've done quite a few tanks like this. Don't have the fuel pump in, remove all the stuff from the flange.
 
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