Sprint in a Basket

[ST13Guy]

Friend took his 2004 Sprint ST apart and doesn't remember how to put it back together. I scoured the archives and reviewed the service manual and still have a few questions. I'm hoping to tap into the collective here on the forum.

Air Box - holes on rear corners. One is a drain (left side) and the other (right side) connected to the silver box?

Fuel connections, which is supply and which is return, does it make a difference? Also, fuel regulator sensor, what does this plug into? The two plugs at the top, drain or over flow hoses of some sort?

Engine Management light is on. Could any of these connections be crossed up cause this error condition?

Appreciate any input you can provide.

[pushr0d]

Your buddy sounds like a shop's dream!

He's lucky to have help.

I can't help with the airbox connections.

The fuel connections are different. The most easily noted are that the 'return' is the 90, hopefully Red in color, which should be aft of the 'straight' connector, which is the pressure side. Be very careful when connecting these to their females, and be sure to fully depress the locking ring when making the connection. It is quite sharp, and can nick the o-ring.

Nothing connects to the atmospheric vent on the regulator.

The two small rubber hoses are the 'scupper' drain from the tank fill hole, and the 'tipover' valve. They make up to the two nipples on the tank, the drain being aft. You'll note a hole in the transmission housing and a wire loop on the front of the centerstand (IIRC). The hole is for the 'tipover' line, and the loop is to contain the drain line.

Before you remount the tank, make sure both the nipples are clear. The drain nipple is prone to plugging.

The CEL will illuminate if you've energized the bike with any of the various connectors not connected. Assuming you have the bike properly put together, it should extinguish after three heat cycles.

[ST13Guy]

Pushr0d,
Thanks for the reply. The bike starts, in fact I seen the Engine light was lite during the test ride. Wasn't sure what it was until I parked and checked the MOM.

Thinking back, I could of turned the ignition on to make sure I got a toot out of the horn. Which based off what you said, could be the fault with the CEL.

I'll pull the tank tonight and give everything a good look just to make sure I didn't miss something. I think I lucked out with the fuel lines, I made the connections based on how the lines laid naturally. I'll look just to make sure. I figured that ring at the bottom of the engine was a retainer for one of the lines from the tank.

Thanks again.

[pushr0d]

Sounds good!

Be very careful pulling and remounting the tank. The Sprints are bad about breaking fuel fittings.

Make very sure the hoses are not being pressed into the tank by interference with drain hoses, etc. against the frame.