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25-10-2007, 12:40 PM
| | Full Member | | Join Date: Sep 2007
Posts: 430
| | | Setting up WT603 installation?
Hey everyone,
I am a bit curious at the moment to how the accelerator cable mounts to the carby throttle. Do i use my standard one?
I read up something about a return line to my fuel tank, this part i don't understand how u'd connect upto the fuel tank again, does a hole need to be drilled in the tank?
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25-10-2007, 01:04 PM
|  | Full Member | | Join Date: Jun 2007
Posts: 1,254
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the return line is only for when you pump the carby.
i dont have a return line on my x2, because i rarely pump it
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25-10-2007, 01:25 PM
|  | Full Member | | Join Date: May 2006 Location: Broken Hill, NSW
Posts: 344
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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 01:39 PM.
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25-10-2007, 03:36 PM
|  | Full Member | | Join Date: Dec 2006
Posts: 718
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I personally think its a waste of time having the return line going back to the fuel tank,i just vented my walbro return to the ground.
I never have to prime the bulb to get mine started so its alot of hassel for nothing
If i were you sharpy,id run a small piece of fuel line facing towards the the bottom of the bike instead of all the messin about,saves alot of heart ache for if you stuff up the fuel tank drilling attempt
You will also need a reducer piece to reduce the normal size fuel line to the smaller type before it gets connected to the walbro
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