Mk1 TDM850 Electric Fuel Pump Install

[pt65]

Hi All,

 

Man, its hard to find info on TDM's! Well, I just picked up a '92 850 with 8,500 original miles. Almost showroom condition. But, the fuel lines are all cracked, the coolant was black as oil, and a few other bits that probably need attending to.

 

In any case, my major issue right now is a fuel leak.

 

I just changed the fuel lines, but it still leaks. I've narrowed it down to either the o ring type seals on the tank valve / connection (it really isnt a valve since doesnt close), or the fuel pump diaphram membrane. I will start it again this eve and look carefully at the tank valve and fuel pump to see if its dripping down from the tank or spitting up out of the fuel pump.

 

I suspect its spitting up out of the fuel pump though, b/c when its running, it misfires / skips a bit (probably a bad coil since they are OEM and the insulation is likely faulty - I will try the self amalgamating tape method) and just when it does, there seems to be a squirt of fuel out the top of the pump out of the little pin sized hole on left side,just under a flat round tipped metal cover coming from the tank bolt mount. Hope thats clear enough.

 

My question is, since I dont plan to upgrade to an R1 R6 pump any time soon, has anyone dealt with this before?

 

I found the following item on ebay http://www.ebay.com/itm/YAMAHA-XTZ-750-6...19fcbb616f

 

But I think this is a MK2 fuel pump membrane. I suppose I will see for sure if I disassemble the fuel pump beforehand.

 

Man, this bikes a pain to work on. My GSX-R1000, ktm 520exc and kdx 200 are all waaaay easier to work on.

 

Any help, hints, tips will be most welcome!

 

Oh, by the way, if anyone is interested in doing vacation adventure tours in northern California, I'm working on a project to provide rental bikes and guides. Its a dream!

 

Thanks!

 

Pat

[Studley Ramrod]

Hi,  looks like the diaphragm kit should fit your fuel pump, iirc the internals of the mk1 and mk2 pumps are the same.

 

I guess compared to the bikes you mention, the TDM does seem a pain to work on but believe me there are many other bikes that are a lot more painful.

[TYREDNGRUMPEE]

Suggestion.

 

It may be worth you running the engine for a few minutes before you carry on and dismantle the vac pump.

 

Check before to see if there is any trace of fuel in the vacuum line from the pump, back to the engine.

[richarda]

You could get a new pump for a similar cost:

 

http://www.banggood.com/Dirt-Bike-SUV-Fu...44300.html

 

Richard

[pt65]

Thanks for confirming that the membrane matches!

But, that pump looks like the ticket.

Grumpee, why would there be fuel in the vacuum hose, and what should I do about it if there is?

 

This is going to be one hell of a fun adventure bike

[TYREDNGRUMPEE]

Grumpee, why would there be fuel in the vacuum hose, and what should I do about it if there is?

Carry on as you were. I've heard examples where failed membranes lead to fuel down the sucky bits. ( searches for link )

 

http://www.carpe-tdm.net/ipb/index.php?s...4&p=302714

[pt65]

Thats what I was thinking, and a friend confirmed it as well. If the membrane is torn, the vacuum hose might suck fuel.

[alexk243]

Probably going to use a fused relay like this to do the job (change it out to a 10a fuse though)

[alexk243]

Is there any concern with noise of the pump being connected directly to the metal frame with no isolation?

[drewpy]

Is there any concern with noise of the pump being connected directly to the metal frame with no isolation?

i'd make sure that the electric pump uses the rubbers supplied or fuel may froth or damage the pump

[alexk243]

I didnt have any rubber supplied... I used a little bit of rattletrap that I had lying around, how think of an insulation do I need?

[drewpy]

can you use those rubber bobbins which have threads either side?

[alexk243]

I was just using a large hoseclamp... Ill take a picture