This applies to all older fuel-injected models…
A couple years ago the ‘Weber’ fuel pressure regulator on my Cali 1100i (owned from new, since 1996) packed up. This is a fault that can be expected to hit all the early Fuel Injection bikes sooner or later, as the spring side of the regulating membrane vents to air (or, depending on model, into the airbox / inlet). Hence, dust, moisture etc. can easily get in, no matter how meticulously you clean your bike. Over time, the inside gunks up, or the spring rusts and breaks, you name it. And eventually the thing fails…
The bad news: They are currently not available. There are a lot of very well maintained and excellent bikes out there, but without this regulator they just won’t run. Or at least, not run right. I’ve heard of at least one case where someone was close to scrapping an excellent and beloved bike, just because of this issue!
Used ones are obviously both as rare as hen’s teeth, and also almost equally as old, and prone to failure!
The good news: Don’t give up! There is a solution. Yes, the fuel hoses will need a little adapting - but nothing major. Yes, the space under the tank is scarce - but with perseverance, a physically larger unit can be fitted.
For all currently available regulators one must modify the fuel hoses. The Weber unit has a ‘Pressure In’, a ‘Pressure Out’, and a ‘Return’ connection (one with a banjo bolt). It is quite easy to take that off the hose, and just use it with a Jubilee Clip instead (see pic). The new regulators only have ‘Pressure’, and ‘Return’. A brass ‘T’-piece between the ‘Pressure In’ and ‘Pressure Out’ hoses gives the Pressure supply to the new regulator.
I went wrong first. Having found out the technical spec (2.5bar), I managed to find an expensive similar-size and (I thought…)similar spec unit. While she started again, she was extremely rich and un-rideable. Back to the drawing board then…
Next try: a cheap and cheerful, adjustable regulator with pressure gauge from Ebay (see pics). Based on my experience with Mini Compressors, I didn’t trust the gauge - but it helps with the adjusting. I went for an indicated value of around 2.2bar at idle.
Fitting was a bit tricky due to the size (forget the bracket that’s with it!), but with some fiddling I got it to nestle nicely, suspended from its hoses, amongst all the other stuff under the tank. The gauge and adjusting screw are nicely accessible above the r/h cylinder head.
Bottom line, with some £15.- on Ebay, and some modification of the fuel hoses, the problem can be easily overcome. No need to despair, she runs as great as ever!
NOTE: The fuel hose pics show the first (wrong) replacement regulator!
