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 Post subject: Replacing fuel pump undertank electrical harness.
PostPosted: Fri Sep 25, 2020 5:12 pm 
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Joined: Mon Oct 07, 2019 7:24 am
Posts: 40
Location: USA
model: 907 I.E.
year: 1991
My fuel pump began to not activate at times and after a lot of diagnostics verifying that the relays, pump itself and other wiring are OK, I found that the harness piece that goes to the tank has turned to stone from engine heat over the years. Are there any recommended wiring parts that work best or tricks to doing this? I see it needs a 4-wire waterproof plug, but before I order one, what have others done?

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91 907ie
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 Post subject: Re: Replacing fuel pump undertank electrical harness.
PostPosted: Sat Sep 26, 2020 10:30 am 
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Joined: Thu Nov 03, 2011 10:13 am
Posts: 748
Location: Scotland
model: 907 I.E.
year: 1994
Later Multistrada 1000/1100 and the 749/999 series suffer from this issue where the wires break internally inside the potting compound. For these bike's there is now a replacement part available but many owners fixed them by digging out the potting material, replacing the wires and re-potting then with a fuel proof epoxy. The fuel gauge which included the gland assembly isn't listed as available on Stein Dinse's website.
If it's just the connector you are replacing that's easy. It is a 4-way Ampliversal Superseal and these are readily available.

http://www.polevolt.co.uk/acatalog/Small-4-way-sealed-connector-kit.-Red-secondary-lock.-SC4_66KIT.html#SID=54

Image

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 Post subject: Re: Replacing fuel pump undertank electrical harness.
PostPosted: Sat Sep 26, 2020 12:01 pm 
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Joined: Mon Oct 07, 2019 7:24 am
Posts: 40
Location: USA
model: 907 I.E.
year: 1991
The major issue for me is not the connector, but I will replace it with something like you suggest. The problem the wires from the connector up to the tank. They are right on top of the engine with nothing but a common harness sheath to protect it. Everything is brittle. So, I suppose there is nothing more to this than wiring in a new connector with some new wire to the tank inside a heat shield sheath. Tanks for the link.

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 Post subject: Re: Replacing fuel pump undertank electrical harness.
PostPosted: Mon Sep 28, 2020 5:18 am 
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Joined: Mon Oct 07, 2019 7:24 am
Posts: 40
Location: USA
model: 907 I.E.
year: 1991
Attachment:
File comment: This is the harness in question. The sheath and the exposed wires are stiff as a board.
20200927_140507s.jpg
20200927_140507s.jpg [ 171.46 KiB | Viewed 2174 times ]


Attachment:
File comment: Too bad it had no heat shielding.
20200926_195825s.png
20200926_195825s.png [ 932.5 KiB | Viewed 2174 times ]


Attachment:
File comment: The wire colors are not all the same as shown in the color wire diagram. All except the black ground wire change color at the 4 wire plug. All but the ground wire have tiny plastic lettered identification labels around them. These can be moved to the new wires.

V --> W/R (White with Red stripe) = + 12V, label +
Bk --> Bk = - Ground, no label
B ---> Br = Fuel level sensor, label W
Y ---> Gr = Reserve fuel level sensor, label T

20200927_105132s.png
20200927_105132s.png [ 694.1 KiB | Viewed 2174 times ]


Attachment:
File comment: My crude revision of the color wire diagram to show the change in wire colors in this harness section
2020.09.27-21.43.png
2020.09.27-21.43.png [ 92.67 KiB | Viewed 2174 times ]

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91 907ie
Buckeye, AZ.


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 Post subject: Re: Replacing fuel pump undertank electrical harness.
PostPosted: Mon Sep 28, 2020 6:29 pm 
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Joined: Fri Nov 13, 2009 4:33 pm
Posts: 302
Location: San Francisco Bay, California USA
model: 750 Paso
year: 1987
Thank you so much for your careful work and documentation.


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 Post subject: Re: Replacing fuel pump undertank electrical harness.
PostPosted: Sun Oct 11, 2020 2:36 am 
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Joined: Mon Oct 07, 2019 7:24 am
Posts: 40
Location: USA
model: 907 I.E.
year: 1991
I built a new harness with these parts from eBay.

Attachment:
WhatsApp Image 2020-09-29 at 4.09.37 PM.jpeg
WhatsApp Image 2020-09-29 at 4.09.37 PM.jpeg [ 97.36 KiB | Viewed 1780 times ]


16 AWG GXL high temperature automotive wire in colors to match what is shown in the wiring diagram rather than what I found. So, Violet for +12V, Black for ground, Blue for fuel level sensor, Yellow for reserve fuel level.

One 4 Pin Delphi Weather Pack Sealed Connector Kit 14-18 AWG

Three 1/4" insulated male spade connectors (from my own supply)

One 4.8 mm insulated male connector (sold in pack of 20)

One insulated metallic heat shield sleeve 1/2" (sold as 3 ft strip)

I connected the other half of the Weather pack connector to the main harness. The final product worked well, but it did not solve the problem. Rechecking everything, one of the relays was not reliable I cleaned the contacts and it's good for now, although I need to replace the two FI relays.

Attachment:
WhatsApp Image 2020-10-06 at 4.01.27 PM.jpeg
WhatsApp Image 2020-10-06 at 4.01.27 PM.jpeg [ 127.99 KiB | Viewed 1780 times ]

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