VincentHill
Needs a life
Posts: 6520
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posted October 24, 2004 05:49 PM
Cable & Hose Routing 101
All of my recent problems can be traced back to one thing! Improper routing of the Hoses and use of the Spring anti Kink coils. The way kawasaki shows is to run the out let line "Around" the return line. It also shows that the 2 lines come through the frame, that the Return is on the Outside (Closest) to the frame. I actually had it all this waym but did not use the Coils correctly. I have now re-routed the lines so that the outlet hose is on the outside and the fuel line comes off of the Pump makes a gentle curve down and then through the Frame.
Make sure when you are raising the tank that you do not pull it up too far and if you do, make sure that the Spring Coils are in place and push the line back through the area between the Frame and the Plastic splash / Fender pan!
Not being careful cost me two days of going through Hell-0 and a wasted trip on the Dyno Wasted money spent between the Crank Pick up sensor and the Dyno plus fuel, $150.00 Crazy, but I am glad that I got out this light! (Remember I was looking at an ECU and /or a Fuel Pump Close to $1,000 with Over Night Shipping! (The Lord takes care of Babys and Fools! You know that I am no Baby! 
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Made History @ Daytona and still one fast old man!!
  
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beansbaxter
Needs a life
Posts: 5911
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posted October 24, 2004 06:59 PM
glad to hear it Vincent. now go out and do a victory lap!
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rac4it
Needs a job
Bergie
Posts: 3009
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posted October 25, 2004 04:13 AM
Are you going back to the dyno? How much power does it make now.
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Bagster
Zone Head
Posts: 630
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posted October 25, 2004 05:41 AM
So when you lowered your tank it was kinking the fuel line?
What a "simple" fix!
Glad to hear you worked it out Vincent. 
Persistance pays off!
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VincentHill
Needs a life
Posts: 6520
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posted October 25, 2004 07:06 AM
quote:
So when you lowered your tank it was kinking the fuel line?
Persistance pays off!
YES!
I plan to go "Back" to the Dyno Tuesday.
Yes I did a Little Dance and woke up all of the Neighbors.
This has just got to rank as the #1 Stupid thing I have done (or not Done / Seen) in my life! WOW
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Made History @ Daytona and still one fast old man!!
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psycho1122
Pro
Posts: 1608
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posted October 25, 2004 07:09 AM
KAWASAKI Service Manual eliminates this potential problem.
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You say PSYCHO like it's a BAD thing!!
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VincentHill
Needs a life
Posts: 6520
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posted October 25, 2004 09:21 AM
quote:
KAWASAKI Service Manual eliminates this potential problem.
Would you believe I have the Manual and it is because of the "Original routing" and raising the tank a "Lot" caused it. The listed routing is (Looking down from the top behind the bike) is to have the outlet hose on the inside (The right side) then wrap the Hose around the inlet hose. When you raise the tank very high, it pulls the Lines back to the point that outlet hose "Slips" down and goes farther backward and eventually can cause this problem. Understand all of this started with the Hoses routed correctly!
Because of this, I changed the position of the hoses so the the outlet is now on the left and when the tank comes down, the hose now makes a curve down and through the Frame. That is possibly why there is a Limiter that keeps the tank from going up but so high. Remember, I have a cut off tank and no limits on how high I can raise it, which is why, Stock Applications do not aply sometimes.
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Made History @ Daytona and still one fast old man!!
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