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Thread: My Sudden Death Experience

  1. #31
    apriliaforum expert kzmille's Avatar
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    The potting does not seal fuel. The brass cores in the plastic have O-rings on them which seal the fuel. The connections are soldered to each end of the brass core.
    This is America. Use your turn signals or WE WILL KILL YOU

  2. #32
    apriliaforum expert rblue02's Avatar
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    Quote Originally Posted by kzmille View Post
    The potting does not seal fuel. The brass cores in the plastic have O-rings on them which seal the fuel. The connections are soldered to each end of the brass core.
    Ok. Does fuel attack solder ? Or did Aprilia just do a poor solder job ?
    '02 Futura, Blue
    94.5k miles and all is well.

  3. #33
    apriliaforum expert kzmille's Avatar
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    No, I don't think fuel attacks solder. I think there were just a lot of poor or cold soldered connections.
    This is America. Use your turn signals or WE WILL KILL YOU

  4. #34
    apriliaforum expert RAS's Avatar
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    Quote Originally Posted by kzmille View Post
    No, I don't think fuel attacks solder. I think there were just a lot of poor or cold soldered connections.
    Our ethanol laden fuel does attack the OE potting however.

  5. #35
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    apriliaforum newbJoin DateDec 2017LocationSt Albans, UKPosts5

    Hi
    Thanks for the info. I checked the fuel pump connector located next to the battery and there was power coming to it, but I haven't checked from connector to and around baseplate, but will do now, thanks. If that seems fine is it worth removing the pump and checking that



  6. #36
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    apriliaforum newbJoin DateDec 2017LocationSt Albans, UKPosts5

    Hi
    Thanks for the info. I checked the fuel pump connector located next to the battery and there was power coming to it, but I haven't checked from connector to and around baseplate, but will do now, thanks. If that seems fine is it worth removing the pump and checking that?



  7. #37
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    apriliaforum newbJoin DateDec 2017LocationSt Albans, UKPosts5

    Hi
    Thanks for the info. I checked the fuel pump connector located next to the battery and there was power coming to it, but I haven't checked from connector to and around baseplate, but will do now, thanks. If that seems fine do you think it's it worth removing the pump and checking that?



  8. #38
    apriliaforum expert RAS's Avatar
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    Quote Originally Posted by Squeak View Post

    apriliaforum newbJoin DateDec 2017LocationSt Albans, UKPosts5

    Hi
    Thanks for the info. I checked the fuel pump connector located next to the battery and there was power coming to it, but I haven't checked from connector to and around baseplate, but will do now, thanks. If that seems fine is it worth removing the pump and checking that


    You can check resistance across the fuel pump from the harness. If it's infinite, you'll likely need to dig the potting out from both sides to get at those connections. If my experience is repeated, the inside potting will dig out easily with a small, sharp screw driver. i had to carefully drill and dremel most of the potting on the outside.

    After it was al soldered up, I used the Caswell stuff, but JB Weld will likely hold up well.

  9. #39
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    Ok, thanks for your help

  10. #40
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    Ok, I'll have another go and let you know, thanks

  11. #41
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    Update, the problem was a loose wire going into the pump. A bit tricky to fix but it's now done. Thanks for your help.

  12. #42
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    Update, the problem was a loose wire going into the pump. A bit tricky to fix but it's now done. Thanks for your help.

  13. #43
    apriliaforum prov-nov
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    Any troubleshooting gurus have ideas for confirming that a very intermittent stall is a fuel pump problem? It's HOT up here in the Pacific Northwet, and 3 times recently my bike has just died (once at a light, twice while riding ~35-40mph). When riding, it felt just like running a tank dry. I managed to pull over, and within 30 secs or a minute, the bike would start again.

    I have 37k miles, and just got back from a 1500-mile trip with no mechanical problems at all.

    I'd rather not dig into the tank without being sure that's what's wrong, but I don't know how to catch it being wrong when it's so infrequent. (Perhaps somebody can tell me it's not actually that dangerous and nasty to pull the fuel pump assembly off the bottom of the tank? Whenever I smell raw gas fumes, I'm afraid I'm going to blow something up!)

  14. #44
    apriliaforum expert deefred's Avatar
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    The side stand switch can also cause this when you are driving.
    However If the bike doesn't start after putting gear in neutral it cannot be the side stand switch.
    2001 RST Futura in stream Silver.
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  15. #45
    apriliaforum prov-nov
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    Quote Originally Posted by deefred View Post
    The side stand switch can also cause this when you are driving.
    However If the bike doesn't start after putting gear in neutral it cannot be the side stand switch.
    Thanks, that helps. I definitely clicked into neutral after I coasted off the road, and I didn't have any trouble (other than a known-weak battery) spinning the starter, so I'm feeling slightly better about digging into the tank. (If I do a good job, at least I won't have to dig into it again!)

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