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Discussion Starter · #1 ·
You know after you've done the FF and are putting the fuel cap mount back in the tank hole.
How the hell do you make it get back in!!!!!

My one wont go down, almost like the seal has swollen, it pops out.
I can't even get in in and hold it to screw those stupid little pointy screws in.

Any ideas?

Cheers:)
 

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you must take the rubber gasket and line it up properly on the filler before you try to push it back into the tank, don't start with seal in tank but on filler. when you do it this way it easily fits back in the tank.
 

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fuel cap

i found this hugely tedious as well. Besides being really patient and gradually working around it i also very gently used a soft rubber mallet. Utimately i put a slight amount of grip solvent (for golf grips but lots of stuff would work) around the o-ring and this did the trick. It evaporates quickly but is slick before doing so.
 

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Discussion Starter · #5 ·
All done.
When I pulled the tank bits off I never noticed that the rubber seal slipped beneath the lip of the filler mount.
It looked like thats where it went, but no way would it go in.
Just looked at it logically and figured it must be obvious and it was. Put the seal around the filler lip, rubber mallet tap, all good.:D

Just doing the last bits from a total tear down and a bit of bling and mods etc. Hopefully all going this weekend.

Never realised how easy it is to install a Power Commander too.
Brought a PCIII from USA.
Cost here NZD quoted $650.
Brought direct from a place in the US $390 NZD after conversion rate.
Nice of the US dollar being low, or ours being high!:D
 

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Excel Addict
2001 900SSie
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5,343 Posts
Relocate the filter next time

Others have also done this.

Get some fuel injection tubing. Inside the tank replace the filter with the correct length tubing, the outside run the tubing to and from the filter.

This will save time (or mechanics time/money) and angst.

Richard
 

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Is there any downside to placing the fuel filter outside the tank? Assuming that it's located away from excess heat and properly attached to something of course.

not sure what the purpose was in locating it inside the tank in the first place... fully understand that there must be a screen before the pump to protect the pump mechanism itself, and a filter after the pump to protect the carbs/FI/engine, but why put this whole contraption inside the gas tank? Just to save space?

Has anyone moved the whole setup out of the fuel tank?
 

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Others have also done this.

Get some fuel injection tubing. Inside the tank replace the filter with the correct length tubing, the outside run the tubing to and from the filter.

This will save time (or mechanics time/money) and angst.

Richard
Have you noticed any problems from your relocation? I am about to do the fuel filter and am toying with this idea.
 

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2001 900SSie
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Have you noticed any problems from your relocation? I am about to do the fuel filter and am toying with this idea.
No problems at all. I relocated it 8 years ago.

Guessing that is 25,000 miles / 40,000 km external to the tank.
 
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