Fuel Filter Fitted
 

Just finished fitting the filter. Thanks for all the advice

It all went fairly smoothly except that the drain plug was stuck, so rather than risk snapping the allen key or rounding the head, I drained almost all the fuel by holding the open tank filler over a bucket, and, it appears from the stinging sensation and the smell, my legs ;)

As I was warned, the pump assembly sealing ring was a bit of a bitch to get seated properly as it seemed to be a little bit too "baggy" and kept popping out. I didn't have any cable ties, so I managed to seat it (I think) pretty well by getting 3 longer bolts into the threads and then tightening each bolt a turn at a time to squeeze the plate back into the tank. The seal was popping out near the front a little, but I managed to guide it in with my finger. I hope it's sealed properly - there is still a little bit of fuel in the tank and it isn't leaking which is a good sign, however, when I put a gallon in tomorrow, I'll know for sure!

I noticed that the plate flange(?) doesn't seat quite flush all the way round and that there is an approx 1mm gap between it and the bottom face of the tank at around 10 and 2 o' clock with the tank upside down and facing away from me.

I had a look at this carefully and it appears that either:

a) the bottom of the tank isn't flat at those points
or
b) the flange was bent slightly when I eased it out using the 3 bolts through the spare holes method

Anyway, I'll check carefully for leaks when I put some more fuel in tomorrow.

I also noticed when I fired the bike up that the fuel pump seems a hell of a lot quieter now. I'm hoping this is because it isn't having to work as hard pushing fuel through a clean filter and that someone isn't going to post something along the lines of "that means the fuel lines are reversed" :lol:

One final thing - how the hell do I get rid of a bucket full of petrol? :puzzled:

[Edited on 23-4-2006 by zhed44]

The o-ring should be tight, I would recommend getting a new one. From memory it shouldn't be baggy, mine was and leaked, the new one was nice and tight.

But fingers crossed!

Empty the fuel back into the tank, or have a bonfire!!!

Filter it through a bit of clean rag............

Wouldn't recommend re-using the fuel, mind you at todays prices!!
Barbie season is just around the corner, you could always impress your guests with a nice flambe'!!!

Decided to put the petrol in the car in the end as I DGAF if that breaks!

Any ideas on the non-petrol disposal related questions anyone?

gap
 

Dont worry about the gap under the flange, when the 3 bolts tighten against the bottom of the tank it has pulled the pump into the correct position it needs to be in!!

THANKS EVERYONE !!! :D