General
This kit is designed for installation on all 1995 and later Buell
(except Blast) Model Motorcycles.
The Fuel Tank Vent Valve was redesigned for 1999 and
later models and retro-fit to certain 1995-1998 models
under a recall. If you have a 1995 through 1998 Buell
Motorcycle that has not been corrected, you may need
to install the new Fuel Tank Vent Valve according to
Buell Safety Recall Bulletin 0815 (B-022). Certain 1995
through 1998 models are equipped with vent valve
assemblies which can prevent sufficient fuel flow which
may cause the engine to stall or misfire. In addition,
under certain conditions, the vent valve can cause the
carburetor to overflow which could result in fire and
death or serious injury. For 1995 through 1998 Buell
Models, see your Buell Dealer for more details on Safety
Recall Code 0815-Fuel Tank Vent Valve Assembly.
A service manual is required for correct installation of
this kit. If you do not have a service manual, get one
from your Buell Dealer or have your Buell Dealer install
this kit. Incorrect installation of this kit could result in
death or serious injury.
NOTE
A Service Manual for your model motorcycle is available for
purchase at your Buell Dealer.
Installation
NOTE
When performing the following Steps, use 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
To protect against shock and accidental start-up of vehi-
cle, disconnect the battery cables, negative cable first,
before proceeding. Inadequate safety precautions could
result in death or serious injury.
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
1.
Disconnect battery cables, negative cable first.
An open flame or spark may cause a fuel tank explosion
if all traces of fuel are not purged from the tank. Use
extreme caution when servicing fuel tanks. Gasoline is
extremely flammable and highly explosive. Do not
smoke or allow open flame or sparks anywhere in the
area when working on fuel system components.
Inadequate safety precautions could result in death or
serious injury.
2.
Remove gas cap.
3.
Carbureted Models: Drain fuel tank. Disconnect hose
clamp and fuel supply hose from fuel supply valve and
drain fuel into suitable, clean container. See applicable
Service Manual, Section 4 for complete, detailed
procedure.
Fuel Injected Models: Relieve pressure from fuel
system. See applicable Service Manual, Section 4 for
complete, detailed procedure. Drain fuel tank.
a.
Using suitable external fuel pump, such as a Gas
Caddy, pump fuel from tank and into a suitable,
clean container.
b.
See instructions for external fuel pump for correct
use.
4.
See Figure 1. Cut cable tie securing vent hose to fitting
and remove vent hose from fuel tank.
Even with the fuel tank completely drained, a small
amount of gasoline may leak from the bore when the
fuel supply valve is loosened or removed. Thoroughly
wipe up any fuel immediately and dispose of rags in a
suitable manner. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
5.
If the fuel supply valve requires cleaning or repair, refer
to applicable Service Manual, Section 4, for complete,
detailed procedures.
6.
See Figure 1. Remove the fuel filler cap and O-ring.
7.
Remove the eight self-tapping screws from fuel clamp
flange and remove fuel cap flange.
1
WARNING
1
WARNING
1
WARNING
1
WARNING
1
WARNING
1
WARNING
BUELL ACCESSORY GAS CAP KIT
Kit Number 61861-01Y (Chrome)
-J02248
REV. 12-18-01
1 of 4
