FUEL TANK KIT FITTING INSTRUCTIONS

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1 A.Tank Fitting FUEL TANK KIT FITTING INSTRUCTIONS 1. Remove side panels and seat, disconnect the battery. 2. Remove SAS valve from LH frame guard and disconnect at plug, remove frame guard. 3. Remove rectifier from RH frame guard and disconnect the breather pipe that connects to the airbox from the guard end. Disconnect the throttle cables from the handlebars and thread through the frame guard and reconnect. Swing out frame guard and remove the two rubber pipes that connect to the re-breather system (triangular moulding) and remove frame guard. 4. Remove coil from frame and then remove the spark plug cap. (Do not pull on the HT lead but grip plug cap with pliers or soft grips). 5. Undo intake boot clip and remove the four rubber mount bolts (M6) from airbox.

2 6. Lift up the rear of the airbox and before removing from frame; carefully disconnect wiring plug and rubber pipe from underside of airbox. Once airbox is removed put clean tissues or cloth into intake of injector assembly. 7. Re-fit radiator mounting bolts with replacement washers, washers to go between radiator grommits and frame. 8. Cut cable ties that hold wiring for SAS valve and rectifier wiring to frame. Disconnect large brown connector plug on LH side of frame (can be very tight). Disconnect other connector to rectifier on RH side of frame and remove rectifier and wiring loom from bike. 9. Use a grinder to remove paint from coil fixing bolt hole lugs. Fit ignition coil to supplied bracket with original screws with HT outlet at lower, as per photo, and secure to frame with new screws (M5 x 12). Re-route and fit HT cap as shown.

3 10. Fit rectifier bracket to coil bracket with M6 x 15 screws supplied, and fix rectifier to bracket with original screws. Unscrew lower coil bracket bolt and re-fit with earth connector for rectifier (as shown). Route rectifier wiring as shown, above coil, and reconnect. 11. Remove RH upper engine mount bolt and replace with adaptor bolt, as supplied, and re-fit SAS valve with M6 x 15 screw as shown. Reconnect plug.

4 12. Fit tank mounts to frame where shown, but DO NOT tighten the screws. 13. Fit reduced crankcase breather tank, as supplied, to RH side of frame and reconnect pipes (in correct positions as shown on breather moulding diagram, secure with original screws. 14. Slide tanks over studding and position on to frame tubes whilst centering frame mounts. Fit M8 plain nut and washer on to studding and loosely tighten. Insert and loosely screw in M6 x 80 screws into lower side panel mounts on radiator. Once these lower bolts are hand tight and the tanks are correctly positioned then the upper tank mounts can be fully tightened. 15. Check tanks sit securely on to frame, if in doubt, repeat the previous operation. 16. Remove both tanks.

5 17. Re-route rectifier wiring to LH connector, as shown. 18. Refit airbox, first reconnecting plug and pipe to underside of airbox. Take care not to foul any wiring or throttle cables. Lightly screw in front two M6 bolts then lower rear of airbox on to intake and tighten. Reconnect breather pipe on RH side from airbox to crankcase breather moulding as shown. 19. Re-fit tanks and secure on studding using M8 locknuts, as supplied. NOTE Always use M6 x 80 screws to position tank along with the studding. 20. Remove M6 x 80 screws and slide side panel into slotted metal plate on tank and loosely tighten M6 x 80 screws. Pull side panel to insert original M6 bolt and snap locating pin into frame. Tighten front lower M6 x 80 screws fully. 21. Gently lift away front of side panel and screw in M5 grub screw into front brass insert in tank. Leave around 6-8mm protruding and then press firmly on outside of side panel to make a mark with the screw point on to inside of side panel. 22. Remove side panel and drill 9 mm hole using mark inside left from grub screw. Refit side panel and use M5 x 12 screw supplied to secure front of side panel to tank.

6 FUEL TANK KIT FITTING INSTRUCTIONS (cont) B. Fuel Pump Adaptor Fitting 1. Ensure as much fuel is removed before starting work. 2. Remove rear wheel and mud flap. 3. Remove the four M5 screws that connect fuel pump housing to bottom of tank. (Fuel may come out as housing is lowered.) 4. Lower pump assembly, un-clip from pump and remove lower moulding.

7 5. Remove banjo bolt and banjo from pump adaptor plate and side pump adaptor plate over plastic tube, with O ring recess facing up. Using a 4mm diameter drill insert into threaded hole and drill through plastic tube. Then drill another hole 10 mm above the top of the adaptor plate and clean plastic tube from burrs and debris 6. Slide pump adaptor, then O ring over moulding and insert back into pump top; attaching with two clips. Push assembly back up into tank and secure with four M5 x 45 bolts, as supplied. NOTE Before re-inserting pump assembly into tank, check electrical connectors and corrugated fuel pipes are not kinked or disconnected. 7. Align fuel pipe banjo as shown. 8. Unscrew rear brake reservoir and fit fuel tap with 35 mm spacer tube and M6 x 50 screw and clamp reservoir between tube and frame. 9. Fit fuel lines, as supplied and check all connections for leaks before reconnecting battery. 10. Fit T shaped breather tube assembly to tank caps.

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