Fuel sensor.

[Twinz]

Today, I went after the potting compound from the inside (pump side) of the harness. After carefully chipping away with a small screwdriver, the green pump wire popped out. I pried some more around the other wires, which seemed like they were firmly attached. I screwed-up with my pencil soldering iron by melting a little of the plastic wire harness housing, but I'm sure I can still cover everything with the Caswell epoxy. One question...the harness has an o-ring seal and the two screws holding the harness are tight. Does anyone know if any sealant is necessary on that o-ring (didn't seem to be any)? Anyone have a torque number for those 2 bolts?

[RAS]

Should think that the O-ring by itself should be sufficient. It seals onto the metal pump plate, correct? It's not like there's much pressure there.

If the bottom of the tank stayed flat, that big o-ring on the pump plate (w/o red goo) would have been good enough. The service manual calls for that anaerobic stuff on the big o-ring, but I doubt any of the bikes were built with it from the factory. Mine sure was not.

[maro6613]

That's sure good to hear. Did you use the stuff that takes 24 hours to cure or the 5 minute version?

I used the 24 hour version. Figured I might as well do it right, didn't want to have to tear the tank back down in a few days (or ever again, hopefully).

[RAS]

Strength-wise, I've always had better success with the slower set stuff. Hopefully it'll also be more resistant to the EtOH as well.

[Twinz]

Hey, EVSY, how's your sensor repair coming?

The Caswell epoxy has set up nicely and is quite hard and transparent. I'll give it another day to cure before reinstalling the tank. I did change the filter while in there, and the tank flange seems quite true so hopefully I'll have no leaks!

[Twinz]

My Fut's reassembled, doesn't leak (so far) and starts...yippee! Now EVSY, how are you coming with your repair?

[EVSY]

My Fut's reassembled, doesn't leak (so far) and starts...yippee! Now EVSY, how are you coming with your repair?

I must admit to buying a new harness as there was one on the shelf for about £60 and have got some Loctite for repair of the old one to have as a spare,I could,t chance it for my big Euro holiday!

[Twinz]

Glad to hear you're back on the road!