Well here it is

 

It seems the black housing had a cracked ear, it gave just enough room to blow out the O ring. Overnighter the part for tomorrow. However, I did put it back together and took her for a spin. She sounded different, much better. The fuel pump is very quiet, no popping, no missing. I rode for 30 min no problem. Brought her home took it back apart and will replace black piece tomorrow. The black piece is $13.00. Make sure to order a new black piece as it did not come with kit. I say that because it the FPR Fuel pressure regulator can't come back unless a ear on the black piece is broken. The black piece is the problem not the FPR.

 

Great job.... good find....

FWIW... that housing has failed enough, that there is an aftermarket, metal housing available, so you'd never have to deal with that again... but it's a bit pricey..!!

https://shop.traskperformance.com/pr...ulator-housing


Again, good job... now you can just enjoy the bike...!!

 

Thanks, I will check into the metal housing.

 

Good find. Appreciate all the info you took the time to post for the rest of us. Was it much work to get the assy out and work on it?

 

When I saw you say it was "pricey" I was almost scared to look. But $70 is not really too bad for a really quality part. Wonder why the OEM plastic piece breaks the ears off? Brittle from the fuel it's always in, but is it the - vibration or mounting bolt stress that causes it to break? Both?

 

I said "pricey" because you can get the OEM housing for like $15... But that Trask housing is a quality part, and you certainly wouldn't need to change it out again...

Why the OEM housing brakes is anyone's guess... but if it in fact always fails at the same spot, IMHO that would suggest it is not properly engineered for it's application..

While it's a known problem, it's not like you read about them breaking on a daily basis...

I haven't needed to replace the guts in the fuel tank of my '03 softail.... yet.... but always had it in my mind that I would change out that regulator housing "while I was in there" regardless of it's condition...

 

I would have to say it's a little intimidating at first. Just take your time and it's not really very hard. If I had to do again it would absolutely be a Breese.