Broken fuel pump nipple repair

28073 Views 75 Replies 24 Participants Last post by NikoFrancx, 22 d ago

RICZ

Discussion Starter · Sep 28, 2018 (Edited)

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.

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3

Reactions: 5

61 - 76 of 76 Posts

Vinish

· #61 · 11 mo ago

Maddog1960, I want to buy one of these to have around just in case. However, I am confused. Is this a replacement nipple for the fuel nipple on the bottom of the tank? Is this the nipple that the elbow connector shown in post #3 in this thread connects to? Assuming the answer to both my previous questions is "yes", then what is the nipple shown in the second large picture in your post #26 in this thread? This is the picture that shows what looks like your new nipple with wires coming out of it. If this is the fuel connection nipple, why would there be wires coming out of it?

WeekendRider

· #62 · 11 mo ago

Vinish said:
Maddog1960, I want to buy one of these to have around just in case. However, I am confused. Is this a replacement nipple for the fuel nipple on the bottom of the tank? Is this the nipple that the elbow connector shown in post #3 in this thread connects to? Assuming the answer to both my previous questions is "yes", then what is the nipple shown in the second large picture in your post #26 in this thread? This is the picture that shows what looks like your new nipple with wires coming out of it. If this is the fuel connection nipple, why would there be wires coming out of it?

I believe that it is just an optical illusion . If you look at the nipple he made that is also pictured in post #26, there is a chunk out of it that someone later asked about. His reply was that he drilled it a little off-center (his prototype was made without his lathe.) I believe the chunk lines up with the wires giving the illusion the wires go down the tube.

Vinish

· #63 · 11 mo ago

Hahaha. I think you are correct, WeekendRider. I was even the one who asked about the notch and I still did not understand that the wires were really behind the fuel nipple. My bad. Thanks for clearing this up.

Maddog1960, what is the process for buying one of your nipples? (That sounds way too demented and kinky

) There is no hurry as I do not currently need one and will only keep it around in case I need it. Thanks.

Reactions: 1

IndyVictory

· #64 · 11 mo ago

I bought one of his nipples (hard to not laugh typing that).

You drill and tap the fuel pump, thread the new nipple into the pump, and the bike fuel line will connect to the nipple. Seems easy enough, but hope to never use it.

I do not think anyone would be against waiting to get these. Even at a higher price it would be worth it. Do what you can in the time you have, if they don't want to wait, oh well.

Font Automotive tire Gas Audio equipment Electronic musical instrument

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depot picker

· #65 · 11 mo ago

Nipples.

Reactions: 1

Alwhite00

· #66 · 11 mo ago

So it's a straight 3/8-16 thread, correct? What do you use to seal the straight threads? NPT threads are tapered to seal but may not work for this....

Vinish

· #67 · 11 mo ago

And how do you turn the part into the plastic after the new threads have been cut into the plastic? There appears to be no "flats" on the part to be gripped by a wrench. Channel locks, pipe wrench, or vice grips would, of course, work but all of these would scar up the smooth outer cylindrical surface which mates with the fuel elbow. Scarring up this mating surface does not seem like a good idea.

WeekendRider

· #68 · 11 mo ago

I believe he provides some thread tape with the part (not gonna call it a nipple!) My 2 cents is that hand tightening is plenty. Give me a wrench and 9 times out of 10 I'm gonna gorilla it.

JK, but I'd be afraid that someone would over do it and crack the plastic.

WeekendRider

· #69 · 11 mo ago

I've considered buying one to have just in case. But I'm likely to lose it, so I'm hoping the OP continues to make them for the community. I think it's a great part! And if I needed one and it took him a week or two, well that's just how it is. My choices are clear: buy one now, buy one when I need it and wait, or buy a whole new pump if I'm in a hurry (assuming I could get a pump quicker than he'd make the part, which probably isn't likely.)

Maddog1960

· #70 · 11 mo ago

Vinish said:
Maddog1960, I want to buy one of these to have around just in case. However, I am confused. Is this a replacement nipple for the fuel nipple on the bottom of the tank? Is this the nipple that the elbow connector shown in post #3 in this thread connects to? Assuming the answer to both my previous questions is "yes", then what is the nipple shown in the second large picture in your post #26 in this thread? This is the picture that shows what looks like your new nipple with wires coming out of it. If this is the fuel connection nipple, why would there be wires coming out of it?

The wires are not coming out of the nipple those are the fuel pump wires. My part is designed so that if you accidently break off the plastic nipple part which is part of the fuel pump base you can drill and thread the opening to accept the nipple, I made this when mine broke off so that I didn't have to buy a complete assembly (about $400.00 if you can find one. The nipple is made to connect to the hose just like the original one from the factory which is part of the base. Mine is made of steel so it will not break off once it is threaded into the base the base is about 3/8" thick so there is plenty of material to tap. The one in the picture on my fuel pump is one I made using a drill press, hacksaw and files that is why the hole is off center. If you have any more question, feel free to let me know, the biggest thing is you have to drill and tap the base to accept the new nipple. Making sure no plastic fragments are left inside the base to cause you problems. I ended up removing my fuel pump from the tank and taking it apart. I recommend if you are not mechanically inclined to find a mechanic that is willing to do it.

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clink

· #71 · 11 mo ago

Maddog1960 said:
Well I sell them thru paypal.me/victoryfpn for $50.00 and I have five made at this time they use a 9-1.25mm thread. I have a Harborfrieght tap and die set so this at the time seemed the best choice because standard size threads seemed to jump from either to small or to big. If you order one make sure to include address and I will send out ASAP. Thanks.

Ctdkid said:
Do you still have any of the nipples made up? I just broke mine off tonight and this looks like a solid repair. What is your PayPal? I can send the money ASAP.

tommyarmour said:
I understand this is a pretty old thread. Hope it is still monitored. I'm pretty sure my nipple is cracked or broke. I installed my tank, took a 300 mile trip and gas mileage significantly reduced. I could see moisture under the tank area. When I originally removed the tank I disconnected fuel line behind right side cheese wedge. Avoiding the nipple under the tank. When I reinstalled the tank I must of bent it causing a crack.

Back to fixing the nipple. By your pics it seems like your metal/aluminum piece is pretty long... Are you just sliding the long metal piece in the pics in until the plastic lines back up applying glue/adhesive? Or are you cutting it? I didn't see a picture of you cutting the metal tube for a flush flit. You said tap the tubing into the pump... How much tubing should be tapped in? 1/4" inch or more? Sorry for being a newb and a little confused. I'm also concerned about drilling into the broken nipple to the pump/tank side. My concern is drilling some plastic into the pump area. I'm guessing that Drilling should allow the plastic to pull towards the bit, just drill from underneath the tank. I'm starting to figure it out. LOL

Doesn't this restrict the flow of gas?

Maddog1960

· #72 · 11 mo ago

Ctdkid said:
If you don’t mind shooting me an email to confirm the payment [email protected]. Not sure if my address will be attached as well.

Samuel Yacino
29 Whittemore rd
North Grosvenordale CT

Sorry don't see any money deposits. Plus, I live in Arizona where we have not had power since Sunday, we just got power today and today is the first time I have been able to use the computer. If you want, I can send money request. I believe I still have a few already made.

Maddog1960

· #73 · 11 mo ago

Be advised I checked my supply and I do not have any more nipples made and unfortunately my lathe is out of commission. I will see if I can fix it, but I believe there is something wrong with the circuit board. Not and electronics guy. I will see what I find but last time it cost me $200.00 for a new board and I don't know if the guy is still making them. If anyone has a lathe and wants to make and sell them, I can make a schematic drawing on how they are made just let me know but you need a lathe unless you are like me and really good with tools and want to spend about three hours to make one by hand. Sorry guys I will let you know what happens.

Alwhite00

· #74 · 11 mo ago

Maddog1960 said:
Be advised I checked my supply and I do not have any more nipples made and unfortunately my lathe is out of commission. I will see if I can fix it, but I believe there is something wrong with the circuit board. Not and electronics guy. I will see what I find but last time it cost me $200.00 for a new board and I don't know if the guy is still making them. If anyone has a lathe and wants to make and sell them, I can make a schematic drawing on how they are made just let me know but you need a lathe unless you are like me and really good with tools and want to spend about three hours to make one by hand. Sorry guys I will let you know what happens.

Please post up the drawings with dimensions. Thanks.

IndyVictory

· #75 · 11 mo ago

I think one thing is certain there will always be demand for nipples.

I've only had tank off once so far and my nipple is fine.

NikoFrancx

· #76 · 22 d ago

RICZ said:
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.

Do you need to super glue the 2 broken ends together since you have the friction fit? Mine didn't quite line up and mate.

61 - 76 of 76 Posts