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Fuel Pump O-Ring information

Buellxb Forum

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i'm seeing a fair amount of fuel pump issues lately as our beloved buells continue to age gracefully. several on-going discussions on this board as well. the removal/replacement/upgrade/cross-over scenarios have been well covered but there continues to be consistent questions regarding the O-rings. everything you can possibly need to know to source same.
ALL XB MODEL FUEL PUMP FRAME TO PUMP MOUNTING O-RINGS
1-factory part # is P0121.02A8 SUPERSEDED by same # with an A as suffix. the A means nothing. just a vendor tracer. both part numbers reference the same identical part. still available in unlimited dealer quantities as of 3-22-2017
2-available thru many aftermarket suppliers such as OringsandMore.com IMPORTANT: any replacement ABSOLUTELY must be either nitrile or viton or it will leak like hell in short order.
O-RING SIZE IS: 3 inches ID-------3/16th inches thickness. these are the 2 dimensions you will need to source any aftermarket replacements
3-OringsandMore.com great source and priced right. their part # is 151V.
4-i keep O-rings in stock. dealer retail is approx. $6.20 each.....my cost $3 each. if you get stuck PM me and i'll send you some.
NOTE: each ring must be lightly coated with either recommended silicone O-ring lube or a light grease prior to assembly. and carefully tighten the bolts in sequence as to not crack the pump housing.
hope this info helps.
 
Last edited:
Of coarse it helps !
Big thanks to you John, for taking the time to post this info up.

I have one question, should these types of O rings be refrigerated ? I ask because I have noticed when storing rubber bands and some other none food things, they do last a lot longer than if just left out or put in a draw ?
 
njloco said:
Of coarse it helps !
Big thanks to you John, for taking the time to post this info up.

I have one question, should these types of O rings be refrigerated ? I ask because I have noticed when storing rubber bands and some other none food things, they do last a lot longer than if just left out or put in a draw ?
Click to expand...

not that i'm aware of kenny. i'm sure they're UV sensitive but typically what i do with neoprene or nitrile or viton O-rings is keep them in small zip-lock plastic bags in a dedicated shop drawer. they stay fresh for years stowed away like that. at least that's my experience with them.
 
Just changed my fuel pump. I had the well documented ground wire rubbed down to the bare metal and grounded out causing a false low fuel light. Yep, Oringsandmore.com had the rings. I ordered extra and good thing I did since I somehow scratched the first set and the fuel pump leaked.
Harder was finding fuel resistant heatshrink to fix the wire.
 
I changed out a 08 , it had a bad tea bag, rather than rebuild it I went all new, yes it was like $369.

pump2.jpg
 
lunaticfringe said:
i'm seeing a fair amount of fuel pump issues lately as our beloved buells continue to age gracefully. several on-going discussions on this board as well. the removal/replacement/upgrade/cross-over scenarios have been well covered but there continues to be consistent questions regarding the O-rings. everything you can possibly need to know to source same.
ALL XB MODEL FUEL PUMP FRAME TO PUMP MOUNTING O-RINGS
1-factory part # is P0121.02A8 SUPERSEDED by same # with an A as suffix. the A means nothing. just a vendor tracer. both part numbers reference the same identical part. still available in unlimited dealer quantities as of 3-22-2017
2-available thru many aftermarket suppliers such as OringsandMore.com IMPORTANT: any replacement ABSOLUTELY must be either nitrile or viton or it will leak like hell in short order.
O-RING SIZE IS: 3 inches ID-------3/16th inches thickness. these are the 2 dimensions you will need to source any aftermarket replacements
3-OringsandMore.com great source and priced right. their part # is 151V.
4-i keep O-rings in stock. dealer retail is approx. $6.20 each.....my cost $3 each. if you get stuck PM me and i'll send you some.
NOTE: each ring must be lightly coated with either recommended silicone O-ring lube or a light grease prior to assembly. and carefully tighten the bolts in sequence as to not crack the pump housing.
hope this info helps.
Click to expand...

:up: :up: :up: thanks John!!!! :up: :up: :up:
 
lunaticfringe said:
i'm seeing a fair amount of fuel pump issues lately as our beloved buells continue to age gracefully. several on-going discussions on this board as well. the removal/replacement/upgrade/cross-over scenarios have been well covered but there continues to be consistent questions regarding the O-rings. everything you can possibly need to know to source same.
ALL XB MODEL FUEL PUMP FRAME TO PUMP MOUNTING O-RINGS
1-factory part # is P0121.02A8 SUPERSEDED by same # with an A as suffix. the A means nothing. just a vendor tracer. both part numbers reference the same identical part. still available in unlimited dealer quantities as of 3-22-2017
2-available thru many aftermarket suppliers such as OringsandMore.com IMPORTANT: any replacement ABSOLUTELY must be either nitrile or viton or it will leak like hell in short order.
O-RING SIZE IS: 3 inches ID-------3/16th inches thickness. these are the 2 dimensions you will need to source any aftermarket replacements
3-OringsandMore.com great source and priced right. their part # is 151V.
4-i keep O-rings in stock. dealer retail is approx. $6.20 each.....my cost $3 each. if you get stuck PM me and i'll send you some.
NOTE: each ring must be lightly coated with either recommended silicone O-ring lube or a light grease prior to assembly. and carefully tighten the bolts in sequence as to not crack the pump housing.
hope this info helps.
Click to expand...

Correct thickness is 3/32" (not 3/16") http://www.badweatherbikers.com/buell/messages/3842/772831.html?1459726014

Dash number 151, Viton, 3" ID 3-3/16" OD 3/32" CS, Durometer 75A

1$ each on Ebay https://www.ebay.com/itm/Viton-Heat...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649
 
As an eBay Associate we earn from qualifying purchases.
You also need 2 different sizes o-rings for fuel line banjo fitting - replacement for kit part number P0198.02A8:

1 o-ring dash number 010, Viton, 1/4" ID x 3/8" OD x 1/16" CS, Durometer 75A - 0.05$ per each vs 3$ from dealer https://www.mcmaster.com/9464k15

1 o-ring, metric, Viton, 7.1mm ID x 10.3mm OD x 1.6mm CS, Durometer 75A - 0.2$ per each vs 3$ from dealer https://www.mcmaster.com/9263k137

And 1 o-ring for fuel pump drain plug - replacement for part number P0127.02A8 is o-ring dash number 011, Viton, 5/16" ID x 7/16" OD x 1/16" CS, Durometer 75A - 0.06$ per each vs 2$ per each from dealer https://www.mcmaster.com/9464K16
 
Last edited:
All, Perhaps you might remember my fuel pump grief ( plus a LOT of grief from fellow Buellers) with my 2009 ULY back around Labor day. I decided to replace the entire fuel pump with a new one from Saint Paul HD. It was expensive but seemed cheaper in the long run rather then messing around with O rings, adaptations and ebay who knows what.


conclusion was to find an in-tank fuel filter that would catch all the junk as the fuel goes into the tank. I think I found the filter but they are all for screw top tanks rather then the Buell style with dogs. Solution is to remove the filler/cap and mount the top of the fuel filter under the cap. I will let you know how that goes.

Aside from all that, it is wet, rainy and miserable so the next trip is if I go the first bit with the bike in back of the truck down to NorCal-say and bomb around for a few days.

Opto


The reason my fuel pump failed is that the internal filters were blocked solid and overworked the pump.
 
Extra filtering is good but I think most of the problems come from the time some of these bikes are not used and the fuel just sits in the tank. I find it hard to believe that in this day and age that there are that much impurities coming out of the gas nozzle.
 
If you are planning to change fuel pump pressure regulator it will likely go with new o-rings. If you are planning to reuse the fuel pump pressure regulator you will need two different sizes o-rings.

1 pressure regulator small o-ring - dash number 109, Viton, 5/16" ID x 1/2" OD x 3/32" CS, Durometer 75A - 0.1$ per each https://www.mcmaster.com/9464K44

1 pressure regulator big o-ring - dash number 118, Viton, 7/8" ID x 1 1/16" OD x 3/32" CS, Durometer 75A - 0.2$ per each https://www.mcmaster.com/9464K82
 
Loco,

For sure sitting around time is not good for bikes, or bikers for that matter. Lunatics idea of storing with Avgas, or at least unleaded, is a good idea. The black crud in my internal fuel filters had to come from somewhere. I do not know the PO's regimen as far as storing over the winter went. Probably best to attack the problem on all fronts.

I get pretty remote on some trips and those little funky mountain towns could have iffy gas. Anyway, I am fitting a tank fill filter-- see how it looks in a few months.

Opto
 
You also need 2 seals for inline fuel pump filter - replacement for part number P0164.K is piece of gasoline resistant petroleum hose 5/16" ID x 9/16" OD x 5/8" long, Buna-N - 0.07$ per each vs 7$ per each from dealer https://www.mcmaster.com/54605K33
 
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