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Thread: XB9S – running very roughly – tried various fixes – need some expert help!

  1. #31
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    LunaticFringe - many thanks for the further advice. I have just ordered metal inline filter. Cant find a fuel level sensor yet in UK but will get one.

    Reading through forum - mixed views on can you get a fuel pump out (2003 XB9s) with the swing arm installed if disconnected from the shock so it drops down?

    Anyone able to confirm either way having done it?

  2. #32
    Senior Member lunaticfringe's Avatar
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    Quote Originally Posted by CrashBurnFly View Post
    LunaticFringe - many thanks for the further advice. I have just ordered metal inline filter. Cant find a fuel level sensor yet in UK but will get one.

    Reading through forum - mixed views on can you get a fuel pump out (2003 XB9s) with the swing arm installed if disconnected from the shock so it drops down?

    Anyone able to confirm either way having done it?
    yes sir....always my pleasure and appreciate the acknowledgement which is extremely rare on here.
    YES....you simply remove the rear tire and the lower shock mount from the swingarm and drop the arm down to its lowest postion. see the vid below. it's the best i've found and the first 5 minutes or so show removal. every XB fuel pump has to be wiggled and cajoled a bit to come out but it will.
    when replacing it be sure to smear a light coat of either O-ring silicone lube OR chrysler style lubri-plate lube onto the 2 housing O-rings....then install. if not done the O-rings tend to tear when you slide the pump into the frame spar.
    if you can't source the fuel level sensor over in Olde Blighty let me know and i'll send you one over. USPS first class air is $14 to anywhere in the UK.

    here ya go.....

  3. #33
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    LunaticFringe - many thanks again and thanks for the offer re the level sensor - just managed to get one in the UK - its a tiny thing. Got some silicon grease and all the other bits and just some carpentry to make a support for under the exhaust and I will be ready to do the job! The video makes it look straightforward. I will report back when its done.

  4. #34
    Senior Member Cooter's Avatar
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    IMO it is easier and much more stable to park the rear under an A-frame ladder and hold it up with a motorcycle ratchet strap to the pillion pegs. You don't even need a jack!

    I didn't watch the vid, but you can use molded tinfoil for a makeshift funnel to drain the gas into a container and put painters tape on the swing arm to save from scratches

  5. #35
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    getting closer to fixing it and pre strip down test showed just 11psi (should be ~49psi) BUT - Got it all apart and the 2003 Buell fuel filter that I was sent is c50mm diameter - which is maybe what a later Buell uses and my one is just 1.25" Dia (c31.6mm) and the 50mm wont fit in the housing.

    Anyone know the industry part numbers for an early Nov 2002 - so 03 model Buell XB fuel filter with a 1.25" dia fuel filter? Then I can try and source one quickly in the UK?
    Also the Orings on the OUT of the fuel pump look a bit iffy and none in my kit - so anyone know the dimensions as tried what I had in various boxes and none a snug fit.

  6. #36
    Senior Member lunaticfringe's Avatar
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    2003 Buell fuel filter that I was sent is c50mm diameter - which is maybe what a later Buell uses and my one is just 1.25" Dia (c31.6mm) and the 50mm wont fit in the housing.

    paul: are you referring to the sock filter on suction side of pump or round filter on pressure side of pump?

    Also the Orings on the OUT of the fuel pump look a bit iffy and none in my kit - so anyone know the dimensions as tried what I had in various boxes and none a snug fit.

    see pic. are you referring to the ones i've circled? if so just make your own. click my name...then forum posts....and scroll to pump section. i've explained how to make your own out of correctly sized fuel line.

    the factory part # for the filter on pressure side of pump is P0101.02A8 ----- 2003-2009 XB Models SUFFIX B4Q

    f.jpg

  7. #37
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    I should be clearer - it is the metal canister filter on the pressurised side that I am needing - the one on the bike has an outer dia of 1.25" - important as it has to be this dia to slide into the housing. The replacement one I have is c50mm dia - so too big.
    The o rings are the ones fitted to the fuel pump outlet to seal it inside the regulator housing - see pic. with arrow showing ones on old pump and not looking their best.fuel pump o rings.jpg

  8. #38
    Senior Member lunaticfringe's Avatar
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    paul: here's all your needed info below.

    on either side of the original outlet filter....the filter on pressurized side of pump..... I use 5/16" fuel hose rated for submersion in fuel. Gates 27039 and ACDelco 32306 are 5/16" fuel hose that have the J30R10 specification. I used 180 grit sandpaper to gently massage the ends so that they fit into each crevice. the original parts called "filter bushings" have long been listed as NLA and are out of the parts system.

    f.jpg

    your RED ARROW O-rings are factory part # P0125.02A8 NO SUFFIX. order qty. 1 which is total of 3 pieces. i do NOT have the size for them so cannot recommend aftermarket replacements. might be something out there but would have to be "fuel submersion resistant.....like viton. that part # is for late 2002-2005 Buells only as the design was slightly changed and they are not used on later year pumps.


    Last edited by lunaticfringe; 03-18-2019 at 02:44 AM.

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