Install New Fuel Tank Vent Valve (All Models)
The Fuel Tank Vent Valve was redesigned for 1999 and
later models. Certain models of 1995 through 1998 Buell
Motorcycles must have the new Fuel Tank Vent Valve
Assembly installed (Safety Recall Code 0815). If your
model has not had the assembly installed, you must
install the new Fuel Tank Vent Valve (Part Number
93923Y) at this time. The Vent Valve Tool Kit (Part
Number 91432-96Y) will also be necessary for installing
the replacement Vent Valve Assembly. See your Buell
Dealer for more details.
NOTE
All Models: When performing the following Steps, you will
need the Fuel Tank Vent Valve Installation Kit (Part Number
91432-96Y). This kit consists of:
* Fuel Tank Vent Valve Installation Aid
* Fuel Tank Vent Valve Fitting Socket
13. Wipe inside and outside of vent valve mounting hole to
make sure there is not gasoline or excess Hylomar
sealant present.
14. See Figure 3. Using the Fuel Vent Valve Installation aid,
lower the fuel tank vent valve into the fuel tank through
the filler neck.
15. Position the fuel tank vent valve so the threaded portion
at the top protrudes from the fuel vent opening on the
fuel cap flange. Verify hole on top of vent valve is not
blocked by Hylomar sealant and that vent protrudes
completely from hole.
NOTE
The fuel vent fitting is installed DRY. Do NOT use teflon tape
or LOCTITE products when installing vent fitting.
16. Refer to Figure 2. Install new O-ring in groove on bottom
of new vent valve fitting.
17. While holding vent valve with fuel vent valve installation
aid, install fitting and O-ring to threaded portion of vent
valve. Do not tighten. Remove fuel vent valve installation
aid.
NOTE
It may take a few tries and slight rotation of the vent valve to
get the alignment mentioned in the following Step.
18. See Figure 4. Obtain new vent fitting from kit. Align fitting
so right front point of hex is oriented to 12:00 position
when fitting is tightened finger tight. Make sure O-Ring
remains in groove of fitting while tightening.
Do not overtighten vent fitting or attempt to tighten with
standard “click-type” torque wrench. Overtightening
vent fitting will cause it to snap off and fall into fuel tank.
19. Using a Dial-Type torque wrench, tighten vent fitting to
40-60 in-lbs (4.5-6.8 Nm).
NOTE
If fitting nozzle does not point to 12:00 position when
tightening within specified torque range, loosen fitting, rotate
vent valve and try again. Repeat as necessary to obtain
proper alignment of nozzle within specified torque range.
CAUTION
1
WARNING
3 of 4
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Figure 3. Installing Fuel Tank Vent Valve
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Vent Valve
Installation Aid
Figure 2. Installing New Gas Cap Components
New Fuel
Cap Boot
New Fuel Cap
Flange
O-Ring
New Vent
Valve Fitting
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Figure 4. Fuel Tank Vent Alignment
Right Hex Point Should Point to
12:00 Position When Finger Tight
Then Tighten to 40-
60 in-lbs (4.5-7 Nm)
with Dial-Type
Torque Wrench.
Nozzle should
Point to 12:00.
Nozzle
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