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Old 25-10-2007, 02:25 PM
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You will need the following:

1x 500mm x 3mm fuel line with 6mm end
1x metre of 3mm fuel line (car vacuum hose is ideal)
2x 3mm straight hose connectors.
zip ties to secure fuel lines.

Step 1
Drill 1/4" hole in bottom of the fuel tank, picking a location that will not interfere with frame. Take care in drilling the hole as you only get one chance at it.
If you drill the hole to oblong or big it will leak so be cautious.

Step 2
Insert the 3mm fuel line into the hole drilled in tank, pushing the line in until you can pull it out of the top of the tank. Push the 3mm plastic fitting into the end of the line sticking out of the top of tank. Be sure that you push the fitting all the way into the fuel line until it is flush.
Pull the fuel line from the bottom of the tank until the fitting just starts to come through the hole, creating a seal.

Step 3
It will be necessary to temporarily set the fuel tank on the frame to measure for proper fuel line lengths. You may need to take the tank on and off a few times complete the procedure below. Make sure to use the top fairing to locate the tank in the correct place.
Cut the fuel return line to length, connecting it to the return line on the carb.
Remember supply line is on the bottom of carb and return line is on the top of carb (this is crucial)
Install the fuel supply line, the large end to the fuel tank. Use a zip tie or clamp.
Connect the remaining end of 3mm fuel line to the carb, trimming as necessary. It is that you reinstall the original, or new fuel filter. This can be fitted at the large end of the fuel line, near the tank. It is best to find a spot where the filter will come into contact with any other parts, so it does not rattle when riding, You can use a small piece of the original fuel line to connect filter to the tank.

Step 4
Use zip ties to secure fuel line to frame. Do not let the fuel line come in contact with the exhaust pipe or engine.

Re- install the top fairing. Re-fuel and install petrol tank cap. Check for leaks. If there are any leaks in the fuel system, you will need to repair the leaks before starting the engine.
Its not wise to run the engine if fuel is leaking.

Last edited by CLIFFO : 25-10-2007 at 02:39 PM.
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