Zane 650 sport cutting out but not dead

Andy said:
PB2 wins the prize!
😉
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Thanks Andy - having done two in a professional workshop, it wasn't that hard to diagnose from the symptoms. No idea how you managed to get all that out with the tank in situ - can't recall the process, but if you get it back together without removing it you're a clever trevor. If I owned one i couldn't stand it - I'd have to go with Jon's suggestion and move it all outside the tank - I know space is tight (one of the reasons it's such a prick of a job) but I'd find a way!!
 
Thanks one and all for all the help.
Pump turned up today and looks compatible now waiting for hose etc.
Once (hopefully) back together I'll try and share how it went. Not surehow long it will be before I post the result! There could be a lot of spanner throwing in the shed.
 
Well good luck with the reassembly. I’m just about to strip out the tank on my 650 Formula to find out why there is no fuel coming out where it should be. When it goes back together it will definitely have an external fuel filter, but I am still contemplating an external fuel pump as well.
 
Pump in. Lots of practice runs to make sure hose lengths are OK.
I found that I had to use a spare piece if hose as a draw rope to find the end of the new hose(s)
What I couldn't understand was how the original hoses were too short to fit to the end of the pump out side the tank?
I then discovered by accident that the filter goes through the hole in the baffle in the tank.
Once I had got the filter through the hole, more fiddling, suddenly there was enough hose at the bottom of the tank to attach the pump to the hose. I then pushed the pump and flange into the tank and fitted a couple of screws to hold it in place.
Once the pump/flange is attached to the tank and the filter is back through the hole in the baffle plate there is enough hose at the top to attach the top flange.
The other thing that has been puzzling me is that some are saying that the tank needs to be removed. In my case I didn't need to do this to gain acces. But are some tanks different?
I've attached a couple of picks to show the top and bottom 'flanges' which I have gained access to by taking out the rear wheel etc and the fuel injection body.
So it's going back together.
Hope the above is of interest and perhaps of some help to others.
 

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My info was based on experience in a commercial workshop and following instructions from the owner. Could well be that your method would have worked - and saved a lot of grief and cursing!! Well done to you.
 
Andy said:
PB2 wins the prize!
😉
Click to expand...

Bugger, no fair. My gum leaf story was pretty good. But doubt there’d be many gum leaves in the UK.

Actually, I wasn’t suggesting that was the cause, just a good story that popped into the large grey void that occupies the inside of my head, not the devoid (of grey hair) on the outside
 
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chrisk said:
... doubt there’d be many gum leaves in the UK.
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Last time I travelled overseas with my then partner, we sat under a tree on a riverbank in France to eat our lunch of baguette, fromage and vin rouge, when a familiar smell assaulted my nostrils. I looked up, and realised we were sitting under a gum tree. Buggered if I know how it found its way to France.
 
Andy J said:
Well good luck with the reassembly. I’m just about to strip out the tank on my 650 Formula to find out why there is no fuel coming out where it should be. When it goes back together it will definitely have an external fuel filter, but I am still contemplating an external fuel pump as well.
Click to expand...
Well, blow me, it wasn’t a faulty pump or a detached hose etc but appears to have been a failing odyssey battery. New battery fitted and it fired up straight away...
 
piranha-bro2 said:
My info was based on experience in a commercial workshop and following instructions from the owner. Could well be that your method would have worked - and saved a lot of grief and cursing!! Well done to you.
Click to expand...

There would have been cursing, it is easier with the tank out, the other reason is to give it a good clean out
 
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