So after weeks and weeks of trying to get my bike to start, I have finally discovered the problem. The right-angle elbow connector on the fuel line that goes into the fuel pump had snapped inside the pipe. It's not at all obvious and I'd just presumed it was supposed to rotate. I had two fuel lines and the other one had the opposite end snapped off. I took the two good ends and and put a quick-release connector between them to avoid messing with the stock ones in future. Bike fired up instantly and running perfectly. Just thought I'd put it up here in case someone else finds themselves scratching their heads over it.
Spent lots of time going through everything for weeks. In the end I taped the clutch lever down and while pushing the start button I started pushing on things. I happened to push on the elbow connector and the bike fired up but died as soon as I let go. I thought it was the fuel pump at first and it wasn't till I had a look at the other fuel line I had lying around that I noticed the elbow connector was firmly in place and not rotating. I was very close to giving up on it.
Kudos on staying stubborn, your persistence is a true benefit to all that may come across this problem. Now relax ride and enjoy!
A quick disconnect added in the line is a great, and should be obvious, choice. I am going to do that on both my TR and WR250R as both are real wrestling match when it comes to removing the tank. Next time I will just cut the lines and put in the connectors.
Hey Nick, you may want to consider some fuel injection hose clamps, I had the regular ones on my pressure gauge T and they started to seep.
Yes I spoke to someone at a specialist here. They didn't have any that small in stock. I will find some online. My other thought was to use two of these each side with one turned 90 degrees from the other until I get the proper ones. I believe the ones I'm using create more of an oval shape and the proper ones stay round as you tighten. Thanks for pointing it out though.
what is the diameter of the hose (to match the quick release connectors to) ? I am seeing these (6 to 8mm) on ebay, will those work? I am actually having difficulties taking off the gas tank, specifically loosening the clamp holding the R.H. house on the fuel cock.
Would this ZipTy replacement elbow fit the TE630? http://www.ziptyracing.com/husqvarna-gas-tank-elbow/
I ended up following the advice on the forum and took the line off at the fuel injector (I needed that area free anyways, as I am in the painful process of installing power commander v ) But will check my gas tank side line and measure it (since it is off anyways) that connector you referenced looks similar
