Once home I checked my bypass wiring, con checked it while wiggling the wires and found no fault. I also raised the tank and con checked the pump wiring at the connector while moving the pump wires and couldnt fault it. I also checked out the pump relay and couldnt fault it. I swopped the fuel pump relay with the engine stop relay just to see what happens but I'm pretty sure the fault lies in the green wire in the resin block of the pump base plate, a known failure point.

I see the oem Aprilia pump loom is NLA, but there seems to be an after market offering for about £125, has anyone fitted one of these to their bike?

The alternative is to dig the resin out and repair the wire. If anyone has done this, what did you use as the resin substitute?

But £125!!!

JB Weld should do the trick, it's completely fuel resistant once cured.

I found a thread on AF1 where someone experimented by putting some JB Weld in fuel and it softened up. It seems Caswell might be the way to go.

Has anyone used Loctite 518 on the main seal as per the manual? Last time I had the pump out I used a thin bead of aircraft fuel tank sealant outside of the seal but now retired I can't get any more.

After digging the old resin out, I'll see if there is enough slack to bring the joint to the outside of the base plate and put the join there. If not, they'll be soldered and heat shrunk and put back into the new sealant. This will still be better than standard. The wiring has a fuel proof outer, so I'd need to source and buy some if I was to completely replace the wiring and this would mean a joint in the tank to re use the oem pump connector. I've already been into the tank once to replace the filter. I want this to be the last time I go in there again, if possible.

Is this you Spoonz? How much more resin did you have to dig out to get to the other end of the wire? Looking at the photo shows the bottom of that resin block, how did you finish the repair?

What Araldite did you use?

Was yours a full failure or an intermittent fault? 

It seems a pain to have to go into the fuel tank again for a fault that might be else where i.e the fuel pump relay or a wire fault else where (I have swopped the pump and engine stop relays over).

Did you manage to get an indication that wire was definitely at fault or did you go in to cut your loses?

I ended up cutting the wire and I reckon I can re solder them outside of the tank, there seems to be enough slack in the wires. As I need to replace all the resin, Ill probably go with Caswell sealant.

But it means the cutting out fault isnt due to this bit of wiring.

One thing I noticed was the 3 wires from the pump base plate were very hard and brittle, must be due to the heat from the engine over time. Makes me wonder what state the rest of the wiring near the engine is in.

Hoping I dont have to go there.

This is the resin block with wires going straight through without a joint. I mixed the Caswell in a glass container; the stuff left in it appears rock hard.

https://ibb.co/Nd19VKQp" rel="nofollow">

Yep several sections of the loom had be repaired due too brittle wiring, but after 16yrs and 40k, its not new anymore !

Leaked down the side of one of the wires through the sealant.

Decided to cut my loses and bought a Gen 2 pump harness from Griff.

It fits the Gen 1 pump flange but needs the wiring modifying. It has 4 wires through the resin, the 2 extra ones are both earth's. They're redundant as Im keeping the original earth set up. Done the pump, just got to join the original connector to the harness, then another leak check.

Edit: All done, working and leak free.

What a pain in the @rse that was.