Broken fuel pump nipple repair - Victory Forums - Victory Motorcycle Forum
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post #1 of 12 (permalink) Old 09-27-2018, 11:45 PM Thread Starter
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Default Broken fuel pump nipple repair

Some guys on other sites that I frequent, are wanting to see my repair for a broken fuel pump nipple, so here goes.
First, I fatherly lecture as how to prevent this. The manual says when removing the tank, disconnect the fuel line at the lower end. Big mistake IMO. I find I have much more control over what the line is doing when I disconnect it from the top. The nipple breaks because side pressure is applied to the hose when it is connected to the pump and the tank is being lowered.
Now for the directions for the repair.........
1. Obtain a piece of 1/4" steel tubing - aluminum will do if steel is not available. It's sold by the foot and one foot will be more than enough.
2. With the tank angled so the remaining nipple is pointing downward, so nothing gets into the pump, drill the hole in the nipple with a bit that will provide an interference (friction) fit.
3. Do the same with the broken off piece.
4. Measure the depth of the hole in the pump part of the nipple.
5. Measure the length of the broken off part.
6. Cut the tubing to the two lengths added together. It helps to grind a taper on the end of the tubing.
7. Gently tap the tubing into the broken piece until it is flush with the top end of it. It could help to put some adhesive on the tubing and/or in the hole.
8. Place some adhesive like Super Glue on the two broken parts and tap the tubing into the pump, minding the orientation so they mate and the glue bonds.
You are done.
Attached Images
File Type: jpg TANK NIPPLE REPAIR 003.jpg (61.2 KB, 16 views)
File Type: jpg TANK NIPPLE REPAIR 008.jpg (35.7 KB, 15 views)
File Type: jpg TANK NIPPLE REPAIR 009.jpg (41.1 KB, 15 views)

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Last edited by RICZ; 09-27-2018 at 11:50 PM.
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post #2 of 12 (permalink) Old 09-28-2018, 05:10 AM
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It sucks that you had to do this, but because of it we all benefit. Thanks for sharing.


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post #3 of 12 (permalink) Old 09-28-2018, 05:29 AM
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ALSOOOOO to add to this amaizing repair .... You can buy the fuel nipple on the tank side , so please remove the tank nipple and leave the engine nipple , exactly like RICZ says

NO wayyyyy you can buy the fuel nipple on the right hand engine side, impossible task ...

DORMAN 11.8 on the tank side ... no size on the engine size ...

RICZ you are the man of fixing this ... awsome

Andre using TaPaTaLk
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post #4 of 12 (permalink) Old 09-28-2018, 05:53 AM
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I've had my tank off twice now by following the manual with no problems yet but I cringed thinking the worst would happen both times.

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post #5 of 12 (permalink) Old 09-28-2018, 06:12 AM
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For years, I took my tank off by removing the fuel line from the engine. Last time, however, I removed it from the tank instead and quite frankly I thought it was easier.


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S&S Cams, Lloydz filter & ATS +5, PCV, UD pulley, Alto Red Eagle clutch plates
Madstad Windshield, 5000K HID, TriOvals, Memphis Shields wings, Ultimate seat
JVC KD-X35MDT, PBR300X4, Polk DB6502, DaytonAudio ND140-4 rear
HyperLites, LED driving lights, Lloydz dyno 105+H and 117+T
Arlen Ness blinkers, KlockWerks KlipHanger bars, Avon grips

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post #6 of 12 (permalink) Old 09-28-2018, 06:45 AM
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Ha d my tank off many times.the Xct manual says to disconnect it at the tank. No problems.
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post #7 of 12 (permalink) Old 09-28-2018, 09:56 AM
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Quote:
Originally Posted by RICZ View Post
Some guys on other sites that I frequent, are wanting to see my repair for a broken fuel pump nipple, so here goes.
There's that and, well, you like showing off your nipple.

Thank you, we all needed to see it again.
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post #8 of 12 (permalink) Old 09-28-2018, 10:45 AM
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Yeah the manual says tank so that is what I plan on doing soon.
Thanks for the write up it should be sticky here.
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post #9 of 12 (permalink) Old 04-17-2019, 10:17 PM
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Hey Ricz...had a little issue last night, and broke my fuel pump nipple...found this thread, and followed your instructions, and it went smooth..i did add Gas resistant Joint/Gasket maker to the tube, before I slid it into the fuel pump..and used JB weld for the epoxy of the 2 pieces..and it worked great..let it cure 100% tonight, and put it back together tomorrow for the big test..if it works, and I think it will, you saved me over $600Cdn..Just wanted to say Thanks, for sharing ..!
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post #10 of 12 (permalink) Old 04-17-2019, 11:09 PM Thread Starter
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Thanks for the thanks. I'm all about saving money by spending the least I can. And I wasn't going to hand over to Polaris hundred$ for their poor design work. I have already done some work arounds on my Spyder, saving about $200 and I just got it about a month ago.
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2010 Midnight Cherry XR. 7Jurock, Lloydz AF, ATS, AFR tuned VFCIII, IAV, and T-6 and locally repacked pipes = big smiles. SOLD to a dear friend, so it's still in the family."
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Cure that ugly stand up license plate with the cheapest and best laydown bracket. Click this:
https://www.victoryforums.com/11-ven...t-x-bikes.html
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