After two weeks got the replacement fuel pump and replaced it on my own.
BHPian NitNac recently shared this with other enthusiasts:
Two months back went for a solo long ride covering 640 km in a day from Hyderabad to Adilabad and back. While traveling back the bike started behaving oddly typically due to heat as the bike was under hot sun as couldn’t able to find any shed.
My ‘Summer Orange’ started struggle when I open the throttle and the engine light was ON. Thought this was due to heating issue and stopped at a gas station for 30-40min let it cool down by this time it was around 5ish evening.
Waiting did help little but engine light was on as there was no issues i could feel i maintained normal speed and continued to ride. Several kilometers later at low speeds and when i pull the clutch the engine shuts off, need to self-start it on the go and continue the ride. I noticed that this happens only when the RPM is below 1000 RPM. Anyways managed somehow and reached home safely without any major issues.
Next day i started analyzing on what could go wrong. Started searching this forum and internet as below
1. The famous rectifier replacement – Bought 4 rectifiers for 101 INR each and replaced it. Rode the bike for 2-3 kms and the issue was back.
2. Fuel Injector cleaning/replacement – Checked it and cleaned it on. Issue still the same.
3. Fuel filter – This one took time, when on lots of forums and internet searches. As there was no electrical related issues, the only component now responsible was the fuel pump.
Now the component responsible for this issue was identified next is what to do . Since i wanted to further narrow down, I disassembled the fuel tank and the fuel pump and found that the fuel filter is in bad condition hence ordered it from Amazon for 225 INR and replaced it. Test rode the bike and the issue was fixed !!!! Yay !!
Sadly, it lasted for 2 months as new issue started . The fuel started leaking and I noticed this when i was traveling to my work place. Next day, don’t know what to do I disassembled the fuel tank noticed that there was a pretty nice crack at the outlet of the fuel pump (plastic part) as a temporary fix using tissue paper and industrial glue to fix this. Yes the petrol will not let this hold for too long.
Without wasting further time I contacted the nearby automobile shop which sells RE spare part and ordered a fuel pump assembly. This did take time to reach the shop and till then fingers crossed and rewinding things on how could this happen on a 5 year old bike! I ride the bike for 90 kms in a week. Only thing i can guess is that fuel bump is from BOSCH, thanks to German engineering on calculated parts manufacturing and break down period this was bound to happen and its not just for me!
After two weeks got the replacement fuel pump and replaced on my own.
Below is old fuel pump assembly with replaced fuel filter which help me for 2months.
Long crack visible near the connector toward right hand side.
RE part in this box containing MRP and Part number for reference.
These type of clamps aren’t available at the automobile shop hence had to do a jugad by using ring clamps. Works just fine.
Assembled the new fuel pump with existing pipe as below.
Total cost of parts:
1. Rectifiers – INR 101 each, purchased 4, didn’t resolve the issue, reverted to old once.
2. Fuel filter – INR 225/- Stalling issue resolved.
4. Fuel pump assembly – INR 4200/- Fuel leak issue resolved.
Hope this helps.
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