fuel filter mod part 2 for filter removal option

[chrisjp]

ill link back to my original thread so you can follow disassemble and reassemble the fuel pump assembly. also how i added the inline fuel filter, which this mod also requires.

https://www.hayabusa.org/forum/maintenance-do-yourself/175027-fuel-filter-mod.html


this method will be me showing how i took the filter assembly apart...how i put it back together...what worked..what didn't...

 

[chrisjp]

first things first...if you followed the first thread for the dis-assembly of the pump assembly hopefully you now have just the fuel filter assembly in your hands. as we are going to be now working with a dremel i recommend these

 

[chrisjp]

now using the dremel with as small of a disk as possible i followed the line at the top of the filter assembly and cut as shallow as possible to only cut the epoxy that they assembled the top and bottom part with

 

[chrisjp]

next if you have cut well you should be able to pop the top off that holds the filter

 

[chrisjp]

now the fuel filter just pulls out of the top

 

[chrisjp]

as you can see after 45k miles that filter is quite black and clogged. i then dremel'd off the part the filter slides onto. as it is also epoxied in and separate from the top assembly

 

[chrisjp]

now you have the bottom of the filter assembly and the top piece

 

[chrisjp]

now to clean them up i used fine sandpaper to sand them flush so they would mate up easily without alot of gaps. it dont take much so use very little pressure

 

[chrisjp]

THIS PART DID NOT WORK...i am simply showing so you can understand what didn't work. on the bottom of the filter assembly it had "POM" after some google research that stands for Polyoxymethylene in short its a thermo molded plastic that epoxy's and even JBwield does not stick well to. this created problems. so i originally tried this epoxy in the pictures...seemed to hold quite well no air leaks (i would put my fingers in the holes and blow..using soap and water at the seams to see if bubbles. plus i could tell if it was leaking some by both sound of air escaping and it would loose pressure as you blow on it). i epoxy'd it...was concerned it was not gas tolerant as as much research i looked up it didn't specifically say that it was. once i put it back into the tank...i pressurized it and i listened to a POP!!.... OK THAT DIDNT WORK

https://en.wikipedia.org/wiki/Polyoxymethylene

 

[chrisjp]

SO....BACK TO THE DRAWING BOARD. now here i later thought that maybe purple or red pvc pipe fitting would work great...but i didnt think of it till later ...not sure it would hold to POM plastic...and more importantly..is it gas soluble??? so instead i choose to go to harbor freight and pick up for 16$ a plastic weilder as it is thermo molded plastic and can be reheated over and over.

 

[chrisjp]

after reading up and watching some videos on wielding plastic i clamped into alignment and did two quick tack wields

 

[chrisjp]

using the point of the wielder run a groove all the way around to create a valley to fill in like normal wielding. then heat up and push the sides into the groove and smooth out to make the wield. if you need to fill...harbor freight had different rods with different types of plastic but choose to use zip ties as its harder plastic like the POM material the housing is made of. the one side was difficult to put together and i had to fill in because it wasn't a flat side...i had to dig it out a bit and push plastic in and fill it in... it seemed to weild fairly easy except for that one corner with the edge the pressure regulator goes into. NOTE remember the tabs to clip in the white clip to hold regulator in...keep that area clear so you can clip in

 

[chrisjp]

at this point i pressure tested and soap and bubble tested and kept having pin prick leaks. so after a while i went to Walmart and grabbed JBweild quick. mixed it up and put it on the area (JBweild is gas previous) and then "sucked" in so the JBweild would draw into the pinholes and seal it. JBweild still didnt stick that well to the smooth sides of the formed assembly. but did adhere well to the melted and roughed up areas. now later i also found that you need to watch how much you build up as it wont go back into the gas tank. so i had to sand down some in order to fit it into the gas tank.

 

[chrisjp]

refer back to this thread https://www.hayabusa.org/forum/maintenance-do-yourself/175027-fuel-filter-mod.html
for the external filter and set up of the hose's... i soap tested after the JBweild and sanding...no leaks... reassembled and put in the tank and been riding since... personally i felt my first post with drilling a hole was simpler and easier and i wish i had choose to do that. we are still going to see how the pvc pipe glue works as that would make reassembly much easier if it is gas pervious. now all you have to do is change the external filter 10$ a pop...not 250$ like suzuki wants you to. hope this helps

 

[Kahunas]

Awesome write up Chris thanks for being the tester lol ...what about fiberglass resin ..would that have worked ? Just a thought

 

[Busashot]

For this type of "plastic", the best solution for bonding itself back together is this product: BONDiT B-4X

It is some good stuff and should take care of your needs. You can contact this company for more info on it: RELTEK adhesives, sealants and coatings for hard-to-bond substrates and harsh environments.

 

[13B-RX3]

Weird question. When you removed the filter, was there a metal cap on the bottom of the filter paper?