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Old 04-13-2008, 12:45 PM   #1
paochow OP
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O-ring specs for 990 fuel pump?

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.

KTM is charging $57 for two o-rings, 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.
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Old 04-13-2008, 02:03 PM   #2
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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?
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Old 04-13-2008, 02:27 PM   #3
paochow OP
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Quote:
Originally Posted by Rabid Dog
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?
From the other black tanks I saw, I guess they all just look like $hit. Function over aesthetics.
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Old 04-13-2008, 03:35 PM   #4
paochow OP
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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.
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Old 04-13-2008, 11:46 PM   #5
Rabid Dog
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Quote:
Originally Posted by paochow
From the other black tanks I saw, I guess they all just look like $hit. Function over aesthetics.
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.
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Old 04-14-2008, 07:52 AM   #6
paochow OP
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Quote:
Originally Posted by Rabid Dog
but they still can't get me a matched set of caps.
I don't suppose you have a 489 and 499 cap?
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Old 04-14-2008, 04:55 PM   #7
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Quote:
Originally Posted by paochow
I don't suppose you have a 489 and 499 cap?
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.
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Old 04-14-2008, 08:13 PM   #8
Dusty
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Bump

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
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Old 04-15-2008, 07:22 AM   #9
paochow OP
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Quote:
Originally Posted by Dusty
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
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.
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Old 04-16-2008, 07:25 AM   #10
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Safari Tank cap keys

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.....
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Old 04-16-2008, 08:15 PM   #11
paochow OP
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Quote:
Originally Posted by Pom
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
Sounds like a plan.. I put one up here...
http://www.advrider.com/forums/showthread.php?p=6780964
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Old 04-17-2008, 06:33 AM   #12
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My orange tanks look good, well pretty good, but they will get thrashed around anyway.

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. Actually used them on the DRZ in Baja, TWICE!
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Old 05-11-2008, 09:41 AM   #13
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did the o rings come in?? How do they fit?
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Old 09-16-2008, 04:05 PM   #14
unkle_george
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-932 O-rings made of Viton (59.36 mm X 3mm)

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 AS568A dash number is)

That should be close enough.
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Old 09-16-2008, 08:00 PM   #15
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Quote:
Originally Posted by unkle_george
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 AS568A dash number is)

That should be close enough.
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?
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