BizJetGuy

Not sure where to post this question but I hope I put 'er in the right forum...

The fuel pump on my Aprilia is either dead or the wiring to it is botched (I've ruled out the fuel pump relay, its working fine). I put 12 VDC directly to the pump last night through the stock wiring and no-go.

On one of the brand-specific boards, another owner had a similar issue and traced it to a bad electrical connection inside of the potting compound where the wires to the pump and probe exit the gas tank. That owner is in Ireland and used a product called Araldite to re-pot the wire repair. I've done an internet search and it doesn't look like that product is readily available in the U.S.

Is anyone aware of a suitable substitute or where I may be able to pick up some of this Araldite? Anything will do as long as it will create a tight, fuel resistant seal where the wires exit the tank.

TIA!

SheepOfBlue

Not sure what you mean by potting but...
http://www.permatex.com/products/aut...ank_Repair.htm

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BizJetGuy

I looked into the Permatex stuff but it's not exactly what I'm looking for.

I guess the best way to describe things is that there is a hard, resin-like substance that the wires pass through in the bottom of the mounting plate that the fuel pump sits on (inside the tank). If the wiring is the problem, I'll have to remove some of that "resin" stuff, make the wiring repair and then re-seal the area so no fuel leaks from the tank.

Hope that clarifies things a bit. I'll try to take a few pictures this evening, as well.

SheepOfBlue

Kind of what I was thinking. Permatex should work as I have seen it used on plastic bike tanks and metal car tanks. The only question is will it adhere to the resin.

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edp

Araldite is a UK brand name for 2 part epoxy glue - use any slow set 2 part epoxy, it will work just fine.

SomeStrangeGuy

I think this would suit your purpose, I didn't source it though. Was just looking for something similar myself.

Devcon | |

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SomeStrangeGuy

Ah, found this:

Flame Retardant Compounds suit encapsulating and potting., Devcon

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BizJetGuy

Hmmm... that Devcon might work but, as SoB stated earlier, will it adhere to the existing resin?

I've used Pro-seal when sealing aircraft fuel tanks and think some B 1/2 might work nicely but there is still the adhesion question.

This might take some research as I'm not too keen on trial and error when the area in question is directly above a header. For some reason that image of CE on the Aprilia fireball comes to mind.

SomeStrangeGuy

I assume it would bond with it as it would any regular structure. If the goal is to 'reform' the potting compound, you're better off popping the whole thing out and repotting.

btw, I saw a whole bag of potting compound at lowe's in the garden aisle for 1.99$ and I am positive it is fuel retardant.

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seamus

The potting stuff is pretty much just a clear epoxy resin as edp mentioned earlier.

I didn't think of Pro-Seal. That should work pretty well. I know it adheres to kevlar pretty well. Maybe check with the aircraft mechanics at work, they should have some of the good stuff.

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BizJetGuy

I confirmed that there is a bad connection within the potting compound. Out of the four wires going through the bung, three ohmed out good but the power wire to the fuel pump showed about 25 kOhms of resistance.

I put 12 VDC directly to the pump and it spun like there was no tomorrow. At least I saved myself $260 on a fuel pump I don't need.

There is a part number for the short harness and I'm going to try and order that first. If it is not available, then repair is Plan B. I'm going up to Dallas next week and will snag some Pro-seal if I haven't sourced something locally by then.

SomeStrangeGuy

Can you see the busted wire itself? or is it a yank and replace the whole thing?

photos would be good here

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BizJetGuy

Haven't gotten past the ohmming out stage. However, there is no "yanking out" option - I tried

The harness is available (believe it or not) and I replaced my fuel pump order with the harness, saving about $200. It's a standard remove-and-replace at this point but I'll probably repair the damaged harness anyway just so I have a spare at the ready. If this one broke, what's stopping the replacement from the same demise?

edit: No photos yet but I plan on taking a few once my parts arrive, which should be sometime next week.

SomeStrangeGuy

I just sat here laughing for about 3 minutes at this, then realized I am just overtired (edited to fit how I misread it).


That is good you were able to just get the harness - but eventually photos will be necessary, of step 1-1000

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BizJetGuy

Great way to start the day!

That cracked me up! I'll take a few photos prior to my pants arriving to really make it interesting...

BizJetGuy

Update: Even though the wire harness is in stock Stateside, it won't be at the dealer until this Friday or Monday (slowest pony, I suppose) and then the dealer has to ship that to me. The earliest I could be back up and running is next weekend.

Now that I have some time to stew, I started picking away at the existing potting compound (which appears very similar to JB Weld). I took some pictures last night but the wife snagged the camera and I'll have to track those down. Since the harness replacement is fairly straightforward I think I'm going to try to repair the existing harness and maybe shake it down until the replacement gets here.

I'll post photos later if anyone is interested.

SomeStrangeGuy

Hey it's only gasoline vapors and electricity, have no fear

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