Originally Posted by jimbeard
okay I've got the bike stripped down to the tank and just realized on the older (99) models there is no quick disconnect. What's the right method to clamp or plug the lines and keep them from dumping gas everywhere? Anybody have any on-line instructions anywhere.
Replacing the starter relay and this is the first time to take the tank off.
Any help on the older model would be appreciated.
Ahhhh the first time the fuel cell gets pulled off huh??? I remember it well.....well "almost"........
I think I cut one fuel clamp say on the supply line (doesn't matter which though) which meant when I pulled that particular line apart the plastic connector stayed with the hose part that was still clamped. On the other fuel line, say the return, I cut off the opposite clamp so that the plastic connetor stayed with the other clamped hose line,,,,,meaning that when the fuel cell was removed, the two lines from the fuel pump, one would have a clamped and plastic connector on the hose whilst the other would not. This entails easy re install as impossible to get wrong. You just need to get some fuel hose screw clamps to replace those crimped units you cut off.
As far as blocking off the fuel line to stop fuel escaping I always plan this job with only a couple of litres left in the tank. I do have a "standby hose" with either a plastic connector fitted or no plastic connector fitted (depending upon which line clamp/plastic connector you left on the fuel cell fuel lines) and then either clamp/plug this dummy line, or allow fuel to drain into a suitable receptacle by means of your standby hose. If you are gonna do the fuel filter, drain the tank...it's easier/safer to manhandle without fuel in it.
Make sure you don't lose either of the two rubber washers/spacers that are located on the underneath part of the fuel cell where two allen head screws secure the cell to the frame....These little beggars jump outta there at the drop of a hat (once the fuel cell is removed) and you don't realize this until you want to put the allen head screws back in.
Change the fuel filter and air filter at this same opportunity if you can. I mark the large fuel pump nut with a drop of "whiteout" typo correctional fluid so that I can see how tight the nut has to be when I re install.
The air filter is a no brainer.
On replacing the fuel cell I spray the locating pegs at the front of the bike where the fuel cell slips onto with a WD40 spray....makes life easier.
78XS1100E "The Tardis" (ret)
99K1200LT "Beryl Beemer"