09 Fuel Pump inlet? IMS 2.9 gallon tank

[crhansen450]

I recently bought an IMS 2.9 gallon tank for my FI 2009 SMR450. I ran out of gas once on a very short ride, although it was not full, and hoped to occasionally ride to and from work (25 miles each way).

After installing the fuel pump in the IMS tank, there did not seem to be any leaks, but I noticed the plastic that the fuel pump and gasket / o-ring would mate up to did not seem very flat. In addition the fuel pump did not want to push all the way into the tank as it was hitting gently. I tightened the bolts until they were tight. Initially there were no leaks, and the bike sat for a few weeks un-ridden. I noticed the fuel light was on, and filled up, and immediately saw a very fast unsafe leak. I got home, and took the tank off quickly and could see it leaking from the upper of the oval shaped area for the pump (on an IMS tank the bolt holes are at an angle no longer horizontal with the ground. We held a gas can and attempted to pour the gas into it. While doing this I stressed the small plastic 90 degree fitting that the fuel line connects to. I was trying to push the quick-disconnect but, had the tank up out stressing the fitting. I broke the small 90 fitting which goes into the fuel pump, when I was trying to swing the tank up out of the frame to pour the gas out the normal fill top. I really don't want to buy and entire fuel pump.

Does anybody know if just that fitting can be replaced? It does pivot, as though it is a separate part of the fuel pump, but the parts page I went to did not show it as something I can buy. In the picture it is inlet for fuel that the hose numbered 17 attaches to.


In addition my brake light is always on, and I have done some checks. Does anybody have an easy trick to figure out if the front or rear brake switch is the problem?

 

[OlderHuskyRider]

The first 2 pics are mine, I tried 2 tanks from IMS, they both leaked, I gave up, others have used gasoline resistant gasket maker to even out the swooping places where the flange hits the plastic.

The 3rd and 4th pics are from a 630 project where he replaced the plastic elbow with brass.

Unplug each brake light connector (front and rear) and you should be able to see which one is hung up.

 

[Purple Haze]

I haven't tried it but kept the thread in case i need it , apparently a Sherco one works http://www.cafehusky.com/threads/busted-my-gas-hose-tank-connection.30610/#post-281121

 

[crhansen450]

The first 2 pics are mine, I tried 2 tanks from IMS, they both leaked, I gave up, others have used gasoline resistant gasket maker to even out the swooping places where the flange hits the plastic.

Your pictures are the same problem my IMS tank has with leaking. The white residue is where the gas leaked, when the tank was on the bike. The leak is due to the plastic not being very flat where the rubber o-ring mates with it.

I think the trick with tapping the plate may be my best bet.

Purple Haze, Thanks for the thread, it was good to know I am not the only person to break this plastic elbow. Zip-Ty has a really cool brass elbow fitting, but it does not list my year or model. I will try to figure out how to order the Sherco part.

I ended up ordering an aluminum replacement elbow from Husqvarna. BILLF who is a sponsor told me to call his parts department. They had the part in stock an aluminum replacement with o-rings. They were very well aware of this problem.

 

[crhansen450]

Attached are two more pictures for newbs like me. I found a different thread where they pulled the 90 elbow out of the tank with vice grips and a cantilever method. I ended up breaking the elbow and using an o-ring pick to remove the star ring. The remainder of the tube was still lodged in the fuel pump just due to the o-ring pressure. I used the pick and a screwdriver to slowly extract the plastic up and out.

Picture shows the piece with the o-rings on it, the break where the star washer sat and the rest of the original red 90 fuel elbow. I broke the red elbow while hurrying to get the tank off and dump a fresh fill-up which was running out at a pretty fast pace. I am waiting on an Husqvarna aluminum 90 fuel elbow with o-rings, which I hope fits. It will not have the star washer, but the o-rings alone should hold the 90 in place.

Also of note, was the small end, which looks like a pop-rivet, which broke off, you can see one sitting on the shirt (near the top), and the other still holding something in place on the pump.

 

[Purple Haze]

Post some pics of the replacement aluminum 90 and fitment if you don't mind . I'm interested in how it will stay in place .

 

[joedirt]

The o rings won't hold it in place. I machined a hold down clamp from aluminum to keep the new billet elbow from coming out.
I'll take a pic when I get a chance.

 

[crhansen450]

Here are the pictures you asked for. I did not add any type of bracket, I am letting the two o-rings hold the elbow in place. It will pull out, if I take that tank off, for instance. I was lifting it up too high when trying to take off the quick connect. When the elbow comes out, if the bike is not started, nothing happens, a few drips are lost. I have ridden it 6 or more times 50 miles roundtrip on pavement. I did one ride with a short dirt section, but nothing with big g-outs, jumps or whoops. Personally I am fine with the elbow being held by the o-ring pressure. I removed the black rubber protector thing, it kept hanging up as I would put the fuel pump into the IMS tank. Note that the place the red elbow bottoms out is deeper than the husqvarna aluminum elbow. I could see no way to use a star with the new elbow.

The replacement IMS tank, still fit poorly even though it was stamped as being from 05/13. The six holes for the fuel pump, don't really line up well. In addition it appeared to have similar small gaps or warping where the fuel pump should mate up. I used Permatex #2, a black non-hardening sealant that I read about in another thread. I don't have any leaks and I have gotten the bike pretty hot. I have been to work and back 6 or more times. 50 miles roundtrip. The back of the tank had about a 5mm gap where the tank should sit on the frame, when I tightened the front bolt. After I put the seat on and rode, and then took it off and re-installed the new tank it seemed to pop down where it should. I could not see any hoses or anything holding the tank up.

I only get 29 mpg after 3 tanks worth now. The sel1 code shows when I turn on the key, this SMR has the power up stuff done, but SMRs apparently have baffles in the mid-pipe section before the dual silencers.

 

[crhansen450]

I still have not had the elbow fall out using only the o-rings. I have taken this to Pala motocross track and jumped the bike, until the mirrors drooped and needed readjusted.

 

[Bryan Allison]

Here are the pictures you asked for. I did not add any type of bracket, I am letting the two o-rings hold the elbow in place. It will pull out, if I take that tank off, for instance. I was lifting it up too high when trying to take off the quick connect. When the elbow comes out, if the bike is not started, nothing happens, a few drips are lost. I have ridden it 6 or more times 50 miles roundtrip on pavement. I did one ride with a short dirt section, but nothing with big g-outs, jumps or whoops. Personally I am fine with the elbow being held by the o-ring pressure. I removed the black rubber protector thing, it kept hanging up as I would put the fuel pump into the IMS tank. Note that the place the red elbow bottoms out is deeper than the husqvarna aluminum elbow. I could see no way to use a star with the new elbow.

The replacement IMS tank, still fit poorly even though it was stamped as being from 05/13. The six holes for the fuel pump, don't really line up well. In addition it appeared to have similar small gaps or warping where the fuel pump should mate up. I used Permatex #2, a black non-hardening sealant that I read about in another thread. I don't have any leaks and I have gotten the bike pretty hot. I have been to work and back 6 or more times. 50 miles roundtrip. The back of the tank had about a 5mm gap where the tank should sit on the frame, when I tightened the front bolt. After I put the seat on and rode, and then took it off and re-installed the new tank it seemed to pop down where it should. I could not see any hoses or anything holding the tank up.

I only get 29 mpg after 3 tanks worth now. The sel1 code shows when I turn on the key, this SMR has the power up stuff done, but SMRs apparently have baffles in the mid-pipe section before the dual silencers.

Please let me know where you found the replacement billet elbow. We just broke our red plastic one last night.

 

[Bryan Allison]

Please let me know where you found the replacement billet elbow. We just broke our red plastic one last night.

 

[Buzybraza]

Please let me know where you found the replacement billet elbow. We just broke our red plastic one last night.

www.ziptyracing.com

 

[michaelyogi]

www.ziptyracing.com

This one doesn't fit the '09 Husky's. Bill's has the fitting for the '09's. If you need a ZipTy elbow, I got one available that won't work for my '09 310...

I also have an IMS tank. I used a fuel resistant Permatex product to seal the tank/pump. It's been good for three years so far. Good luck.

 

[Buzybraza]

This one doesn't fit the '09 Husky's. Bill's has the fitting for the '09's. If you need a ZipTy elbow, I got one available that won't work for my '09 310...

I also have an IMS tank. I used a fuel resistant Permatex product to seal the tank/pump. It's been good for three years so far. Good luck.

Sorry, I apologize for the bad info! I thought zipty also made one for the 2009 / 450.....