Replace fuel tap with straight hose connector

[alexanderfitu]

Hi all

I have a big leak on the fuel tap of My XJ600 diesel bike.

Im sure the main reason is that the rubber in the seals isnt compatible with Veg oil (most isnt) and its disintegrated, leaking fuel all over my primary belts

It seems as though nobody makes a repair kit either, so I would like to replace it with a staight 8mm hose connector.

Any ideas on how to go about it, I could try and undo the tape assembly and see if there is a way to seal off the tap sections, but the leaking issue would still be there.

[Irn-Bru]

Diesel bike?
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KTM 990 SMT & Suzuki DR-Z 400 SM

[alexanderfitu]

[stinkwheel]

There are numerous XJ600 fuel tap repair kits listed on ebay.

I would imagine most modern seals will now be made to be ethanol proof which is more likely to be oil compatible too.

There are a lot of XJ600s out there but most of the taps I've found by googling seem to attach to the tank via a flange.

So, to fit a hose-tail you'd need to replicate this flange. I'd suggest the easiest way would be by drilling three holes in a rectangular block of aluminium. Use the original tap as a template for the hole positions (maybe need to slightly countersink the inside of the two screw holes where they meet the tank if there is a raised area there).

The middle hole can be drilled and tapped to accept a hose-tail.

I would suggest a 1/4" BSPT male to 5/16" ID Hose fitting. That means you'd need to make your middle hole 7/16" (11.2mm) and tap it using a 1/4bspt tap.

The taper thread is self-sealing. I'd use a thick gasket under the block cut out of either cardboard, viton rubber or (going modern and ratty at the same time) a silicone baking sheet.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[alexanderfitu]

[_Iain_]

Quick thought though.

Why do you even need a fuel tap on an engine that doesn't have a carburettor?

I mean if it runs out of fuel the injectors will just airlock and cause headache anyway, so a reserve is pretty much useless. The vaccum petcock side of things is again, useless as the whole thing would work on an injector pump that won't be moving any fuel unless it's rotating - there's nothing there to flood, no floats etc.

Seems like costly arseache to find and fit a largely pointless component unless I'm missing something?
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Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[stinkwheel]

[Robby]

Assuming the part that fails is the diaphragm in the vacuum tap, just replace it with a normal gravity- fed fuel tap. No rubber parts, and you get to still have main tank and reserve. Also means you can easily turn the fuel off when you remove the tank from the bike.

[gavbriggs]

I have no idea if it will work but you can get a fitting that basically puts a spigot in things such as a header tank for the central heating, maybe you could use one?
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Recent bikes: Varadero 125 - Mod 2 3/2/14 - Bandit 1200 SK4

[Kickstart]

Hi

Fuel tap rebuild kit here:-

https://www.nrp-carbs.co.uk/shop/index.php?route=product/product&path=42&product_id=3474

Found a few pics online and it looks like a fairly normal Yamaha fuel tap (looks like the one on my FZ750 I think). Suspect quite a lot of other Yamahas have taps that could also be used on it.

All the best

Keith
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[alexanderfitu]

[Robby]

The tap seals to the tank with a little rubber gasket or O-ring. If the veg oil or diesel is eating this seal, try making a silicone one out of silicone pipe.

[alexanderfitu]