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Discussion Starter #1 (Edited)
Hi Guy's.

I have done the most stupid thing and broken the outlet plastic tube on the fuel pump under the tank whilst trying to remove the stupid clip.

I just rang the dealers and got a quote for $695 for a new fuel pump ( Made in fkn China ).

Has any one else done this and can it be glued, welded ( or anything else ) back together ?

Any suggestions would be appreciated.

Even if anyone knows what ype of plastic the fuel pump cover is made of would be helpful.

Cheers
AL
 

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Don't Really have a good Answer for you other than this.. Sure Wish someone would make an Easy Fix for this as have heard of it happening too often .. Although have removed my tank 3 times with no mishaps, Scares me every time I do it ... A Good Machinist should be able to sell an Adapter plate with the Nipple like Hotcakes at a Lumberjack Breakfast
 

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Drill and tap for a pipe thread. Get a brass nipple and thread it in. That's what I would do.
There is a guy on another forum that made a plate with a nipple.
 

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1,182 Posts
2009.jpg
1 7517515 Screw 1 Usage
1 7518086 Screw 3 Usage
1 7517845 Screw 1 Usage
1 4011080-385 Asm., Ignition/Fuel Cap, Silver 1 Usage
1 4011080-266 Asm., Ignition/Fuel Cap, Black 1 Usage
2 1015931-266 Tank, Fuel, Spine 1 Usage
2 1015931-1264 Tank, Fuel, Spine 1 Usage
2 1015931-564 Tank, Fuel, Spine 1 Usage
2 1015931-566 Tank, Fuel, Spine 1 Usage
2 1015931-520 Tank, Fuel, Spine 1 Usage
2 1015931-1270 Tank, Fuel, Spine 1 Usage
3 7517525 Screw 3 Usage
3 7517525 Screw 3 Usage
4 5136665 Bushing, Flange 3 Usage
4 5136665 Bushing, Flange 3 Usage
5 5412480 Bushing 6 Usage
5 5412480 Bushing 6 Usage
5 5412480 Bushing 6 Usage
6 7556260 Washer, Flat 1 Usage
7 7547233 U-Nut 1 Usage
8 5412415 Cover, Mount, RH 1 Usage
8 5412414 Cover, Mount, LH 1 Usage
9 5413346 Seal, Fuel, Molded 1 Usage
10 2521169 Pump, Fuel 1 Usage
11 7518923 Screw 10 Usage
12 5413413 Line, Fuel, Tank to Fuel Rail [For 9.5 mm Fuel Tank Fitting] 1 Usage
12 5414150 Line, Fuel, Tank to Fuel Rail [For 11.8 mm Fuel Tank Fitting] 1 Usage
13 7081151 Clamp, Hose 2 Usage
14 5435764 Line, Water Drain 1 Usage
15 5437376 Line, Fuel Vent 1 Usage
16 5435771 Line, Water/Fuel To Ground 1 Usage
17 2520909 Asm., Filter, Fuel

https://www.google.com/webhp?rls=ig#hl=en&gs_rn=11&gs_ri=psy-ab&tok=sbUz9TuSVa2fSdSJt271oQ&cp=19&gs_id=56&xhr=t&q=2521169+Pump,+Fuel&es_nrs=true&pf=p&rls=ig&output=search&sclient=psy-ab&oq=2521169+Pump,+Fuel+&gs_l=&pbx=1&bav=on.2,or.r_cp.r_qf.&bvm=bv.45645796,d.dmg&fp=33b056dbc1d8ff0&biw=1508&bih=874
 

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Discussion Starter #6 (Edited)
Hahaha,

Nice pic Gibson but of no actual use. ( Sealed Unit )
Refer to other answers.

Cheers
AL
 

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Discussion Starter #7

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Discussion Starter #8
Drill and tap for a pipe thread. Get a brass nipple and thread it in. That's what I would do.
There is a guy on another forum that made a plate with a nipple.
Thanx Tarzan
 

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Discussion Starter #10

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IF you end up replacing the fuel pump assembly, be aware that due to excessive breakage, Polaris redesigned the nipple to be stronger somwhere in mid to late 2011. If you have the older style pump, you will also need a new fuel hose as the old quick connect will not fit onto the new (larger) nipple. Maybe your dealer was quoting you for both the fuel pump and the hose? Still pricey though.

Edit: Just realized you're on a Vegas. I know the above is true for the XC, can't confirm for the Vegas.
 

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Discussion Starter #12
IF you end up replacing the fuel pump assembly, be aware that due to excessive breakage, Polaris redesigned the nipple to be stronger somwhere in mid to late 2011. If you have the older style pump, you will also need a new fuel hose as the old quick connect will not fit onto the new (larger) nipple. Maybe your dealer was quoting you for both the fuel pump and the hose? Still pricey though.

Edit: Just realized you're on a Vegas. I know the above is true for the XC, can't confirm for the Vegas.
Thx for the heads up Tony,

The dealer was only pricing the fuel pump and after looking at what the cost is in the USA ( with dealer margins ) it does piss us off over here that we are being taken advantage off.

It's a shame as the mechanics ( just one in brisbane ) is a great guy and helps all of us alot but he is obviously restricted in work, as the parts cost's, force us to look at alternative parts etc and as he is a Victory mechanic i would assume he would be relunctant to put them on the bike just incase there are any come backs.

I personally think that these outrageous costs will deter people from buying a Victory motorcycle over here and they will keep buying Harley Davidsons.

Cheers
AL
 

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I hope my 2011 has the newer style connection. Going to be taking the tank off in the near future to put in the high flow air filter but after reading the numerous threads I am starting to dread it.
 

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$695?

Did I read that correctly???? Well for that kind of money I would go to a good auto parts store and look for this stuff from Permatex for no more than $15 on the high side. It is a tube of "plastic weld" I believe they call it. It is one serenge ( spelled wrong?) with two different chemicals that you push out and mix. Then you apply it to what you want to repair. You have to mix it fast and apply it fast in the summer because it sets up very fast. I have used it on things to glue them back together. I know one guy that patched a small leak on a hydraulic hose and it did not leak for over a week while he waited for the correct new hydraulic hose to come in for the machine. I think it is worth a $15 gamble. If you try this route be sure and check it after you run fuel through it. Also read the back of the package first and make sure it is ok for gas to get on it.-----Now if the package says it is not ok for applications that involve gasoline there is another route. They sell a plastic type fuel tank patch,it might be worth a shot. Either way I would be sure and check it several times over the next few hundred miles to make sure it does not leak. You don't want to see it go up in flames!!!!! I would give it a shot. IF they can section tires back together and have them last they ought to make an adhesive that will glue two pieces of plastic back together and hold up to 75 psi of pressure.
 

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Discussion Starter #15
I hope my 2011 has the newer style connection. Going to be taking the tank off in the near future to put in the high flow air filter but after reading the numerous threads I am starting to dread it.
TNXR,

If there is a definate learning curve to be learn't in all this it is,

TAKE THE FUEL LINE OFF BEHIND THE CHEESEBOARD AND LEAVE IT ON AT THE FUEL TANK.

Cheers
AL
 

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Discussion Starter #16
I hope my 2011 has the newer style connection. Going to be taking the tank off in the near future to put in the high flow air filter but after reading the numerous threads I am starting to dread it.
TNXR,

If there is a definate learning curve to be learn't in all of this it is,

TAKE THE FUEL LINE OFF BEHIND THE CHEESEBOARD AND LEAVE IT ON AT THE FUEL TANK.

Cheers
AL
 

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Discussion Starter #17
Did I read that correctly???? Well for that kind of money I would go to a good auto parts store and look for this stuff from Permatex for no more than $15 on the high side. It is a tube of "plastic weld" I believe they call it. It is one serenge ( spelled wrong?) with two different chemicals that you push out and mix. Then you apply it to what you want to repair. You have to mix it fast and apply it fast in the summer because it sets up very fast. I have used it on things to glue them back together. I know one guy that patched a small leak on a hydraulic hose and it did not leak for over a week while he waited for the correct new hydraulic hose to come in for the machine. I think it is worth a $15 gamble. If you try this route be sure and check it after you run fuel through it. Also read the back of the package first and make sure it is ok for gas to get on it.-----Now if the package says it is not ok for applications that involve gasoline there is another route. They sell a plastic type fuel tank patch,it might be worth a shot. Either way I would be sure and check it several times over the next few hundred miles to make sure it does not leak. You don't want to see it go up in flames!!!!! I would give it a shot. IF they can section tires back together and have them last they ought to make an adhesive that will glue two pieces of plastic back together and hold up to 75 psi of pressure.
I have noticed that JB WELD claims that Gasoline desn't effect there adhesive so i am going to give it ago.

I wish i could buy the fuel pump from the USA but i suspect the dealers over there won't send me one due to there ''Restriction of Trade Terms"
with Polarus.
 

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practice piece

Had another crazy idea. See your from down under,had not noticed that before. If you could get a plastic tube from another source, hardware store, or salvage yard even. Take that tube and break it in half. Then try what ever brand of adhesive you want to try to glue or bond it together. Let your practice piece set up good for a few days out in the hot sun so it drys good. Then take and hook a rubber hose on each end of it. Hang it in a u-shape and fell it up with your local gas, let it sit again for a few days and see if it holds up to the gas. Also if you have an electric fuel pump or even the one your going to put in the bike wire it up and hook it to a fuel source such as in your fuel tank, off the bike and let it pump away to see if it will hold up to pressure. You could pinch the outlet side out of the repair area and let it build pressure to see if it holds,if it holds call it good. You could also just install it on the bike,turn it on and let it pressure up, shut it off and on a few times and check it for leaks. Then when you feel safe with it give it a go and start it up. Run it around the block and then check it again a few times.
 

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Discussion Starter #19
Thx Guy's,

With all the links and help i have been given i printed off all the literature and took it to specialist machinist outfit that specializes in weird and wonderful solutions.

They drilled out the last bit of the broken nipple and then threaded in a metal nipple with 515 adhesive / glue on it so that it locks in absolutely tight.

Works like a charm.

Great to be able to commmunicate with all of u.

cheers
AL
 
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