Buell 61861-01Y User manual

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.
1WARNING
1WARNING
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BUELL ACCESSORY GAS CAP KIT
Kit Number 61861-01Y (Chrome)
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Figure 1. Fuel Tank Components
Fuel Tank Vent Valve
As Appears on 1995-1998
Models
Fuel Tank Vent Valve
1999 and Later Models
Now Required on 1995 and
Later Models
Fuel Hose Vent Fitting
As Appears on 1995-1998 Models
O-Ring
Gas Cap
Fuel Hose Vent Fitting
1999 and Later Models
Screw (8)
Fuel Cap Flange
Fuel Cap Boot Cable Strap
Vent Hose
O-Ring
Fuel Tank
Retention
Hardware
Not in Kit
Shown for
Illustration
Only
1995-1998
Mounting
Hardware
Slightly
Different
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Fuel Tank Shown
For Illustration Only
Remove Fuel Tank Vent Valve
8. Perform the following:
1995-1998 Models-(When not equipped with Fuel Tank
Vent Valve Safety Recall Code 0815). Remove vent valve
by performing the following:
a. While holding vent valve with angled needle nose
pliers, remove fitting from vent valve.
Do not drop or tip the vent valve while removing. It
contains small plastic parts and a small metal ball which,
if dropped into the fuel tank could cause plugging of fuel
tank and fuel lines.
b. Using the angled needle nose pliers, pull the vent
valve from the gasket. Be careful not to tip or drop
the vent valve or check balls.
c. Discard the vent valve, check balls and fitting.
1999 and Later Models and 1995-1998 Models equipped
with New (Recall Code 0815) Vent Valve Assembly-
Remove vent valve by performing the following:
a. While holding vent valve with angled needle nose
pliers, remove the fitting from the vent valve. NOTE:
On 1999 models, you may use the Fitting Socket
(from Installation Kit) to remove the fitting from vent
valve.
b. Pull the vent valve from the gasket and remove
from fuel tank.
9. Remove fuel cap boot and discard.
Install Accessory Gas Cap Components
10. See Figure 2. Obtain new fuel cap boot and new fuel
cap flange from kit.
11. Apply HYLOMAR to fuel cap boot, fuel cap flange and
top of fuel tank.
12. Insert fuel cap boot being sure to align the holes in the
boot with the proper holes in the fuel tank.
CAUTION
Fuel Fill
Decal

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
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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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20. See Figure 5. Align and install fuel cap flange with
screws. Following the order shown, tighten screws to 22-
25 in-lbs (2.5-2.8 Nm)
21. Attach vent hose to nozzle on fitting with new cable tie
(included in kit).
22. Refer to Figure 1 Install O-Ring to Fuel Filler Cap and
install fuel cap.
NOTE
If Fuel Tank Vent Valve Kit was installed, refer to Figure 1.
Install the fuel fill warning decal provided in Vent Valve Kit to
fuel tank. NOTE: Decal indicates that fuel tank should not be
filled above 1 inch (25.4 mm) below bottom of the filler neck
insert. Orient decal so rider can read while seated on
motorcycle.
23. Following instructions in applicable Service Manual,
reinstall Fuel Tank, if removed.
24. Carbureted Models-Install fuel supply line to fuel supply
valve with new hose clamp (small).
25. Fuel Injected Models-Following instructions in
applicable Service Manual, complete tank fuel supply
installation procedures. Pressurize fuel tank.
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion resulting in death or serious injury.
26. Connect Battery Cables, positive cable first.
(Snorkel Inspection)
1999 M2 Cyclone Models Only
1. See Figure 6. Remove the four screws, nylon washers
and air cleaner cover. Inspect snorkel where it mounts to
carburetor.
*If snorkel has four holes, three with fasteners and
one for overflow vent, proceed to Step 2.
*If snorkel has only three holes and no overflow vent,
replace snorkel with correct 4-hole snorkel (Part
Number 27547-96Y). See the 1999 M2 Service
Manual, Section 4, for complete, detailed
procedures.
2. Apply LOCTITE THREADLOCKER 222 (Purple) to
threads of cover screws. Install air cleaner cover with
four screws and nylon washers. Tighten screws to 18-22
in-lbs (2.0-2.5 Nm).
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Figure 5. Tightening Flange Screws
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12
3
45
67
8
Vent
Hose
Cable
Tie
Figure 6. 1999 M2 (Cyclone) Snorkel Inspection.
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Overflow
Vent
Snorkel
3 Screws