No! That's how I broke my nipple - when replacing the tank, the line snagged on something. Disconnecting it at the top, I have more control of the line.
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.
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.
Attachments
21 - 40 of 76 Posts
Agree with Mr. Ricz .... AND always remember the fuel nipple on tank side you can buy from DORMAN, but the engine side is a "special" size that DORMAN does not make, so thats another reason to disconnect from the tankside ....
Andre using TaPaTaLk
My fuel pump pipe broke off about 4 weeks ago and since I could not find a repair part I decided to make my own part using a table top drills press laid on it back and clamp so it would move, hacksaw, files, tap and die set and drilled. My first repair part took me 3 hours to make but this is my new part I am selling. You only have to drill and tap the fuel pump base and screw in my new part it is designed to fit the existing quick connect fitting and if done properly should give you no problems. I have had mine on my bike for 3 1/2 weeks with no problems. I ride my bike to work 5 days and week as I live in AZ. I usually ride year round even at high temps. If you are interested let me know. The one mounted into the fuel pump base is the one I made using hand tools. I now own a metal mini lathe and can make them allot better. Ride safe.
![Screw Auto part Cylinder Automotive engine part Hardware accessory]()
![Screw Auto part Cylinder Automotive engine part Hardware accessory]()
![Auto part Bumper Vehicle Hood Engine]()
![Screw Auto part Subcompact car]()
I do not need one right now. All four of my nipples are intact 
I was thinking about buying one to have on hand just in case I broke one. On the one hand, they can break and often do so at an inopportune time. On the other hand, I know to be super careful when removing and reinserting the quick connect.
I was thinking about buying one to have on hand just in case I broke one. On the one hand, they can break and often do so at an inopportune time. On the other hand, I know to be super careful when removing and reinserting the quick connect.
21 - 40 of 76 Posts
