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.