Fuel Tank Vent Valve - Buell 2002 X1 Handbook

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FUEL TANK VENT VALVE

GENERAL
The vent valve opens to allow gas vapor to escape the fuel
tank and either vent to the atmosphere or to the charcoal
canister on California Models (EVAP-equipped) and closes to
prevent gasoline from leaking out of the fuel tank if the vehi-
cle is tipped at an unusual angle.
REMOVAL
The fuel tank must be drained to perform this service. The
fuel tank does not need to be removed.
1 1
WARNING WARNING
Always disconnect the negative battery cable when
working on motorcycle to prevent accidental startup. If
the positive cable should contact ground with the nega-
tive cable installed, the resulting sparks may cause a
battery explosion, which could result in death or serious
injury.
1. Disconnect negative battery cable.
1 1
WARNING WARNING
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. Inadequate
safety precautions could result in death or serious injury.
2. Remove gas cap.
3. Relieve pressure from fuel system. Drain fuel tank.
a. Using suitable external fuel pump, such as a Gas
Caddy, pump fuel from tank and into suitable clean
container.
b. See instructions for external fuel pump for correct
use.
4. See Figure 4-90. Cut cable tie holding vent hose to fitting
and remove vent hose from fuel tank.
5. While holding vent valve with angled needle nose pliers,
remove fitting from vent valve.
6. Pull the vent valve from the gasket and remove from fuel
tank.
4-104
NOTE
b015r
Figure 4-92. Installing Fuel Tank Vent
INSTALLATION
1. Wipe inside and outside vent valve mounting hole to
make sure there is no gasoline or excess Hylomar seal-
ant present.
2. See Figure 4-92. Using the fuel vent valve installation
aid, lower the fuel tank vent valve into the fuel tank
through the fuel filler neck.
3. 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.
The fuel vent fitting is installed dry. Do NOT use teflon tape or
loctite products when installing vent fitting.
4. See Figure 4-90. Install new O-ring in groove on bottom
of new fitting.
5. 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 Step 6.
6. See Figure 4-93. 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.
4.38
Installation Aid
Vent Valve
NOTE
2002 Buell X1: Fuel System