Facet 40171 install...my story

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Airhead, Aug 18, 2009.

  1. Airhead

    Airhead More human than human

    Joined:
    Nov 22, 2004
    Oddometer:
    2,099
    Location:
    Fear and Loathing in Maine
    So, after burning through 3 OEM fuel pumps in less than 10,000 miles (2 had fried points, one just quit for no reason), I finally decided to install a Facet 40171 and try my luck with that. Just thought I'd go over my experience quickly in case someone else might find it useful...

    I started by ordering the pump and recommended fuel filter from Aircraft Spruce:

    www.aircraftspruce.com

    The filter is listed under the Facet fuel pumps...you need to search for "40171" to find the correct pump.

    I then ordered some Permatex Make-A-Gasket #3 (Aviation grade) to seal the threads on the barbed fitting and the fuel filter:

    http://www.jamestowndistributors.com/userportal/show_product.do?pid=9403

    I had to order the barbed fitting for the outlet side of the pump, since I live in the middle of nowhere and couldn't find one locally:

    http://www.marineengine.com/products/accessory.php?in=2560411

    I bought some 5/16" inner diameter fuel line from the local Napa, and a Unicoil since I decided to run the fuel line straight to the pump inlet, rather than use a bunch of fittings to create a 180 degree bend in the inlet fitting:

    http://www.gates.com/brochure.cfm?brochure=4961&location_id=541

    I snipped the electrical connector off of the old pump, and connected it to the leads on the new pump using weather proof posilocks:

    http://www.posi-lock.com/positite.html

    This allowed me to plug the Facet directly into the stock wiring harness, without having to modify the bike's wiring.

    I used some closed cell neoprene, wrapped around the inlet side of the pump, to mount the stock pump housing, as suggested by cpmodem:

    http://www.foambymail.com/neoprene.html

    This resulted in a very secure fit between the new pump and the stock housing.

    The new pump is a very tight fit, and I had to really work with it to get it to clear the stock skid plate. I routed the inlet fuel line between the pump and the engine casing in order to get it out of the way. I also found that it was difficult to keep the inlet and outlet fuel lines from slightly contacting the edge of the skid plate...I'll keep an eye on those spots and make sure the skid plate does not begin to rub through the hoses.

    The new pump works great, and will hopefully last much longer than the stockers have been. I found the fit to be somewhat difficult, but in the end I found the results to be satisfactory.

    Sorry I don't have pictures...maybe I'll take some to add to this the next time the skid plate is off.

    Jeff
    #1
  2. ADVJake

    ADVJake ***** dweller

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    Hi mate,
    do you have close up photos of the setup?
    #2
  3. kizniche

    kizniche pyro

    Joined:
    Jun 25, 2009
    Oddometer:
    165
    Location:
    Georgia
    I did this upgrade a little over a month ago after I got my 950. Here are some pictures of my final install. I found it to clear the skid plate by a centimeter or two. The hose to the filter has since had a hose clamp put on, and the others replaced with higher quality parts.

    [​IMG][​IMG]
    #3
  4. ADVJake

    ADVJake ***** dweller

    Joined:
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    Sydney, Australia
    cheers mate,
    looks like i need to revise my setup. Im getting fuel line pinching issues when the bash plate is put on.
    #4
  5. Balsta

    Balsta Been here awhile

    Joined:
    Feb 11, 2008
    Oddometer:
    400
    Location:
    Chilly Northern Europe
    My first Facet 40171 (with a quality filter) died after about one season (12000 miles). I'm on the second which has survived this last season. Anyway, it seems from reading this thread my failed Facet probably is an exception.
    #5
  6. K80JIM

    K80JIM Super Tanker

    Joined:
    Feb 8, 2006
    Oddometer:
    556
    Location:
    Huntington Beach Ca.
    This is just a suggestion. If that is a glass in-line fuel filter you might want to replace it with a plastic one. Those were very big about 20 years ago, you could unscrew them and replace just the filter if you wanted. A lot of V.W. shops were putting them on the bugs. I must have seen 25 burn to the ground because if them. We had a repair shop and my brother owned a tow company. They would bump into something metal and crack or maybe just crack from vibration. I could just see that thing being hit by a rock or crash the bike and it hit something or crack from the vibration of the bike.

    Anybody else thinking the same thing or is it just me?

    Good luck with the pump, hope it takes care of all the problems you have had.

    Jim
    #6
  7. firebolter

    firebolter Been here awhile

    Joined:
    Aug 24, 2005
    Oddometer:
    606
    Location:
    Annapolis Mary-Land
    I used the filter from Aircraftspruce for my set up

    [​IMG]
    #7
  8. kizniche

    kizniche pyro

    Joined:
    Jun 25, 2009
    Oddometer:
    165
    Location:
    Georgia
    Thanks for the advice. I now have the metal filter above on order. I had the thought of danger when I realized it was glass and not plastic while installing it. Plastic wouldn't have made me feel much better anyway.
    #8
  9. Swashplate

    Swashplate 50 MSL & 150 KTS

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    +1
    #9
  10. Peanuts

    Peanuts Long timer

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    Why do you need a filter? The fuel taps will have filters in them.
    #10
  11. Swashplate

    Swashplate 50 MSL & 150 KTS

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    I know the tap filter (if the 950 has them) is good enough for the carbs but what about for the pump itself?

    I used the one above pictured above for my install but it on the inlet side of the 40105 pump.

    Note 1: The filter makes a nice easy way to get to the STBD/inlet side of the pump then by using some brass elbows resulting in having the inlet and outlet on the same side just like the stock pump is. Ref: http://www.ktm950.info/ fuel pump, 40105.

    Note 2: I had to swap the fuel line postion in that hose holder under the Rectifier/Regulator to make it fit a bit closer to avoid hitting my TT skid plate.
    #11
  12. Swashplate

    Swashplate 50 MSL & 150 KTS

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    My thinking too, I used to live in So Cal in the 80's and saw these all over the aircooled crowd. Also know a guy who lost his 69 baja for this reason. Magnesium burns very hot and bright too !! They look trick for the show VW's but that about all I would use them for....show.
    #12
  13. Airhead

    Airhead More human than human

    Joined:
    Nov 22, 2004
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    2,099
    Location:
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    These pumps require very fine filters...any crap in the fuel will cause them to seize. I used the one recommended by Facet...

    The only problem I have had is that the leading edge of my pump touches the OE skidplate when everything is bolted together. Not a big deal, just not exactly ideal...

    I also used a Unicoil to protect the inlet hose where it is bent the sharpest...
    #13
  14. kizniche

    kizniche pyro

    Joined:
    Jun 25, 2009
    Oddometer:
    165
    Location:
    Georgia
    Here's the setup with the new fuel filter in place. The line runs the same space the previous filter took up, minus ~5 cm. past the pump to the right where the new filter is installed. The hose has enough slack to where I don't believe a problem will arise. The bend is on the negative pressure end of the pump, so that may be the only issue if the hose becomes soft and decides to buckle and pinch the fuel supply.

    [​IMG]
    #14
  15. bazza950

    bazza950 n00b

    Joined:
    Jun 16, 2006
    Oddometer:
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    Location:
    whitchurch shropshire
    just fitted the facet pump and then discovered that the redundant 4 breather tubes have 7mm connectors into the tank.No one sells 7mm!
    Eventually found that Vespa scooters use this size and ebay (UK) threw up a supplier.
    uniscootuk

    So if you want to buy all the parts before you start - get 4 x 7mm x 10mm long bolts to seal in!
    I have a small issue with the facet filter being too long so might have to remote it, as it touches the bash plate.Unless you know of an answer!
    #15
  16. AdvRonski

    AdvRonski They call me......Ronski

    Joined:
    Feb 4, 2007
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    Wishing I was back in Grand Junction, now in MN

    I wouldn't call those hoses redundant. 2 of them are breather hoses for the fuel tanks, and if plugged could cause fuel delivery issues. The lower 2 are drains for any fuel spillage in the fuel caps, and not really necessary.
    #16
  17. bdefen

    bdefen Been here awhile

    Joined:
    Jul 13, 2005
    Oddometer:
    332
    Location:
    Boise, Idaho - In the heart of Dual-Sport Paradise
    I did the 40171 upgrade 15,000 miles ago....no problems whatsover, but one corner of the pump would just touch the stock skid plate, so I padded the area with some closed cell foam, glued in place.

    As a PM, I replaced the pump last night with a new 40171 and Facet filter, and found that if I rotated the new pump 180 degrees, the offset of the inlet/outlet increased the clearance from the stock skid plate by almost 1/4", so no touching. I left the foam in place on the skid pan.

    I did the original install three years ago exactly as described above, curving the inlet hose with a coil spring enclosing the curve. I replaced the stock electrical connections using those two-wire trailer connectors (SAE?) for the hookup. Also, an electrical tape wrap around the pump wiring covered with a couple layers of shrink-tubing armor. A few zip ties to secure everything, and I'm done. While I was in there, I replaced all the fuel hoses including the tank balance hose.

    After it dries out, I'll cap the inlet/outlet of the old Facet pump (which was still working fine) and carry it as a spare.

    Good advice on avoiding those glass filters. Just R&R the metal Facet filter during your annual maintenance. Cheap insurance.
    :evil
    #17
  18. RedRupert

    RedRupert Brit in the Soviet Union

    Joined:
    Jun 12, 2006
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    Location:
    Riga, Latvia / Bergerac, France / Colchester, UK
    Which 4 breather tubes are redundant?

    You don't need an extra filter. The one in the main fuel tap in the l/h fuel tank does a perfectly good job.
    #18
  19. Orangecicle

    Orangecicle On a "Quest"

    Joined:
    Apr 24, 2007
    Oddometer:
    3,456
    Location:
    West Des Moines, IA
    Here's mine:

    [​IMG]

    I have one elevator bolt through the bottom of the battery box and a zip tie through the original pump mount. It did clear the stock skip plate, but that's now replaced with a Weld86 bash plate. :clap Way more space now, so no problems.
    #19
  20. gefr

    gefr Life is a trip

    Joined:
    Nov 26, 2005
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    Location:
    East Med, Greece
    I believe the loop the inlet fuel line is making is prominent to pinching. These rubber hoses may operate pefectly when cold, but after some time in the hot environment close to the engine, they could soften and seize. I ran the Orangecicle setup with metal elbows. When my Facet died, after 40k kms I replaced it with a used original, with DrBean's electronic circuit.
    Cheers.
    #20