Fuel tank removal

[Cunningham]

I'm taking the tank off to get it painted and have a question for big dogs on the forum. The service manual claims that there's a check valve on the fuel line. Although that does not seem to be the case here.

Please tell me that I don't need to replace the pump! I guess that's not really a question, so how about this: Is this an issue that can be ignored...?

 

[atomsplitter]

The check valve is item #38 in this drawing: Item #36 is the rollover valve, it's part of the rollover safety shutoff.

 

[Cunningham]

The check valve is item #38 in this drawing: Item #36 is the rollover valve, it's part of the rollover safety shutoff.

So you're saying I should replace it...

 

[atomsplitter]

Any check valve downstream of the pump would let gas come out of the tank, it would prevent fuel in the pressurized fuel rail (3.5 bar) from backflowing thru the pump and depressurizing the fuel rail on shutdown.

 

[atomsplitter]

So you're saying I should replace it...

Nope, I'm saying the check valve won't prevent fuel from coming thru the pump.

 

[atomsplitter]

Here are the procedure steps from the shop manual:
1. Note•
Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine with the fuel pump fuse removed.• When disconnected, the fuel tank is self-sealing but a small amount of fuel may dribble from the hose.• To protect the components under the fuel tank, place suitable material over the components to absorb the small amount of fuel that may come from the fuel tank and its fuel lines.
2. Temporarily reconnect the battery, positive (red) lead first and tighten the terminals to 4.5Nm.
3. Start the engine and run until it stalls to drain fuel from the fuel rail.
4. Disconnect the battery, negative (black) lead first.
5. Release the two fixings and remove the headstock harness cover
6. Loosen the instruments clamp fixings and tilt the instruments forward
7. Remove the fixing securing the front of the fuel tank to the frame
8. Raise the front of the fuel tank 50 - 100 mm and disconnect the fuel tank breather hosefrom the evaporative cannister.
9. To release the double check clip, ease the latch away from the connector until therelease buttons are exposed.
10. Disconnect the fuel hose by squeezing the sides of the connector and pulling the hosefree from its spigot on the fuel pump rail. Collect any fuel remaining in the hose in asuitable container.
11. Raise the front of the fuel tank 100 - 150 mm.
12. Disconnect the roll over valve hose from the fuel tank.
13. Disconnect the electrical connector for the fuel pump.
14. Remove the fixing securing the rear of the fuel tank to the frame.
15. Remove the fuel tank's rear fixing sleeve and remove the fuel tank. Make sure the fueltank is lifted over the ignition coils.

 

[Cunningham]

Gotcha. Methinks I might have another more pressing issue:

When I got the tank off it sounded pretty granular in there...

 

[TURBO200R4]

I'm taking the tank off to get it painted and have a question for big dogs on the forum. The service manual claims that there's a check valve on the fuel line. Although that does not seem to be the case here.

Please tell me that I don't need to replace the pump! I guess that's not really a question, so how about this: Is this an issue that can be ignored...?

When you disconnect the fuel banjo bolt the fuel should shut off from the tank so that it doesn't leak like in the picture
if you can find a plug or just ley it drain out that should take care of the drain problem.
i don't see a problem with not repair/replacing as long as it is flowing ok and i am thinking it will flow normal.

 

[TURBO200R4]

Gotcha. Methinks I might have another more pressing issue:

When I got the tank off it sounded pretty granular in there...

will a magnet pick up those pieces ?
i would cut the filter open and if the pieces came from there i think the pieces would be in the pump.
you can take the filter and bang the inlet on a table to see what comes out.
would those pieces be from the gasket where it bolts to the tank?

 

[Cunningham]

will a magnet pick up those pieces ?
i would cut the filter open and if the pieces came from there i think the pieces would be in the pump.
you can take the filter and bang the inlet on a table to see what comes out.
would those pieces be from the gasket where it bolts to the tank?

The filter looks pretty clean. Seems to be flaking off from the inside of the tank.

Gonna try the ol' vinegar soak & baking soda rinse. Unless you cats have an alternative.