O-ring specs for 990 fuel pump?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by paochow, Apr 13, 2008.

  1. paochow

    paochow Bye bye desert

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    A few days ago, I went to swap the fuel pump to my Aqualine tanks and discovered one of the o-rings has a pretty good nick out of it. Set it aside and figured I buy some replacements this weekend, during which time it swelled:baldy.

    KTM is charging $57 for two o-rings:scratch, which is pretty ridiculous.

    Anyone have the size handy for ordering replacements? Based on my measurements it looks like a 2 3/8" ID X 1/8" (or Metric 60mm ID X 3mm) will work for the upper ring, but the swelling may have skewed the size. I'm guessing I want a Viton ring?

    Thanks for the help.
    #1
  2. Rabid Dog

    Rabid Dog Been here awhile

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    Hi Paochow - Same thing happened to me. Fortunately I had a spare fuel pump (OK - So I'm a Boy Scout - Sue me) so I just swapped pumps. The pump is pretty hard to seat correctly, so be sure to do a static test before you mount the tank.

    Now, however, I am looking for replacement o-rings for my spare. So I'll be looking for a reply to this thread as well.

    BTW - The inside of those Aqualine tanks are really dirty (full of plastic shavings and bore-hole cores. Be sure to blow them out.

    Did you ever sort out the finish issues?
    #2
  3. paochow

    paochow Bye bye desert

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    From the other black tanks I saw, I guess they all just look like $hit. Function over aesthetics.
    #3
  4. paochow

    paochow Bye bye desert

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    Looks like the 1/8" wide rings are actually .139" in diameter, so I think I'm going to order up several 60mm X 3mm rings for the top seal, and while I'm at it several 65mm X 3mm for the bottom.

    Anyone know the size of the Viton o-ring for the fuel connection (58507012000)?

    KTM wants $4.49 for a 20 cent o-ring.:baldy
    #4
  5. Rabid Dog

    Rabid Dog Been here awhile

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    Agreed - The orange tanks have a lot more curb appeal. Almost makes me wish I'd gotten an orange bike. Oh well. Sure do like the capacity of these babies. Justgastanks.com have been nice, but they still can't get me a matched set of caps.

    Thanks for the o-ring info.
    #5
  6. paochow

    paochow Bye bye desert

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    I don't suppose you have a 489 and 499 cap?
    #6
  7. Rabid Dog

    Rabid Dog Been here awhile

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    Sorry Man - No joy. There's apparently 40 different keys. They just explained to me that this is SOP (separate caps and keys). They also told me the black tanks all have pock marks. So - I've reluctantly accepted tanks and caps in current condition. As you said - functional - not aesthetic.

    My first fill-up was scary - $39.
    #7
  8. Dusty

    Dusty Long timer

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    Any luck on o-ring sizes, paochow. I have had my tanks off a few time and could use new ones for the fuel connection and would like to take my fuel pump out and put in some new filters.

    If you wouldn't mind sharing any more info it would be appreciated.

    Thanks,
    Scott
    #8
  9. paochow

    paochow Bye bye desert

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    I ordered some -932 O-rings made of Viton (59.36 mm X 3mm), I ended up buying a 25 pack so I may have a few extras if they are the right size. Should have them next week. If not I have a bunch of rubber bands.:doh
    #9
  10. Pom

    Pom Old fart on big bike

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    I have cap key numbers A498 and A490 - at the moment i am trying to track down some non locking billet caps - maybe we should start a thread for us all to exchange caps get a single key for each bike, then maybe we could do if the H&K panniers that don't match with the top boxes.....
    pom
    #10
  11. paochow

    paochow Bye bye desert

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    Sounds like a plan.. I put one up here...
    http://www.advrider.com/forums/showthread.php?p=6780964
    #11
  12. crashmaster

    crashmaster ow, my balls!

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    My orange tanks look good, well pretty good, but they will get thrashed around anyway.:rofl

    As far as the 2 key thing, WTF? I have a hard enough time keeping track of my ignition key, hence part of my offroad kit are lock picking tools.:evil Actually used them on the DRZ in Baja, TWICE!
    #12
  13. Footprint

    Footprint Rat race Dreamer

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    did the o rings come in?? How do they fit?
    #13
  14. unkle_george

    unkle_george Been here awhile

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    I called some giant o-ring distributer here in Portland, Oregon and the guy told me
    "We have a lot of rings, but none of those"

    But he did have some 59.00mm X 3mm so I'm going to try those. (I don't know what the <small>AS568A </small>dash number is)

    That should be close enough. :evil
    #14
  15. Venteuri

    Venteuri I don't give a shit

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    Google is your friend AS568A
    http://www.pspglobal.com/o-ring-sizes.html

    http://www.oringsusa.com/html/size_chart.html


    uhmm.. did I misundertood? and what you meant is that you cant see the number... rigth?
    #15
  16. viola-tor

    viola-tor Needs to ride!

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    Any more specific info on which is the correct size for the two big O-rings on the 990 fuel pump? A link would be handy, I don't know how to read all that technical mumbo-jumbo... :deal :D
    #16
  17. viola-tor

    viola-tor Needs to ride!

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    Here's the answer for posterity:


    #17
  18. gefr

    gefr Life is a trip

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    The oring should be viton 60X3, meaning ID=60mm and thickness is 3mm.
    Cheers.
    #18
  19. kenhaw

    kenhaw 2006 Adventure S EU

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    Is it not possible just putting a nice amount of sealer on the flange instead of
    the use of O rings?
    Has anyone done that?

    Kenneth
    #19