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Help... New problems after trying to put everything back together

2K views 14 replies 7 participants last post by  Paul49 
#1 ·
So after installing new spark plugs, cleaning the oils out of air box and put in new air filter yesterday, I tried to put everything back together... And run into a couple problems... (All Hell Broke Lose?)

1. A few hoses I forgot where to plug them in... See image below... I know the #2 is the gas overflow tube with a inline valve that doesn't connect to anything, I don't know where #1 should connect to...

What about hose #4, which is the thinner tube coming out of airbox, is it supposed to be connected to the #3 (FPR?) on the airbox?



2. After connecting my two fuel lines to the gas tank... the return line (one that had a hose coupler) started to leak badly at connection point, gas just started dripping out... I suspect the o-ring on the fuel hose end (green o-ring) needs to be replaced, as from the photo you can tell it had shrunk a considerable amount and is no longer able to seal.. Trying to find exact size and if I am able to get it from local auto parts stores... Read that it's also good ideal to replace the plastic female couplers with the metal one so I'm gonna order some..



3. The most horrifying finding is that after I put the gas tank back on the bike, I noticed that the tank had "grown" in size and now it doesn't even align with the 3 bolt holes on the frame... ***... Any fix for this? or I need to use some extra brutal force to shove the gas tank back into frame?





 
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#3 ·
It's best to pull the tank when it's nearly empty; they seem to grow more when full. Basically, you want it as dry as possible to make it shrink again, and cold helps as well. If it's not too far grown, you can often get it back on by just starting the nose bolt, then starting the rear ones, then tightening them down front first.

The o-rings are size -011. You can get them from Triumph for $4.39 apiece or you can get a package of 50 from Fastenal for $2. Nitrile is fine, you don't need the fluoroelastomer ones. Definitely time to replace the plastic fittings on the tank and the hose as well! Drop me a PM if you need to replace the lower elbow; I had to buy in quantity and have a couple spares. (The elbows hold up much better than the QD fittings, so you probably don't need to replace it. If you do, though, it's better to replace it before the upper fitting.)

Your #1 and #2 hoses should be identical. It's odd that the valve is there, as it was not supplied as standard on 955s. http://www.triumphestore.com/a/Triu...528/Fuel-Tank-and-Fittings/100066558-0-2.html They've caused a lot of problems for a lot of folks and, for myself, I would ditch it ASAP. (And I have had a wreck where fuel came out of that hose.)

I'm not super familiar with your airbox, but by 2001 Triumph had ditched the hose between the FPR and the airbox and left the FPR open to air. (This happened about the time they switched from the MC2000 ECU with the single, massive, plug to the MC1000 with two separate plugs.) The airbox should have a short-ish drain plug that's open to atmosphere, a wide hose connected to the crankcase, and a thin, corrugated, hose that connects to the ECU.

Cheers,
-Kit
 
#4 ·
Thank you Kit,

So basically I should just take off and throw away those drain plugs from #1, #2, as well as #3 and leave FPR as is?

I have a MC1000 ECU, and my air box uses the flat air filter (old style I think)

On the right side of the bike there are 3 holes, 1 big one for drain, 1 with a 90 degree coupler that's already connected to ECU, and this #3 hose that I think might be originally connected to FPR on this bike.

Ordered orings from dealer but I think I'll just stop by the Fastenal to grab a pack... As I'm the kind of person that's impatient to get things fixed and going...

As for gas tank... I did took it off with a full tank of fuel and left it in backyard for 2 days before I tried to put it back on
 
#5 ·
Yeah, all three of those hoses and the FPR should be open to air. There is a reason for that valve; it keeps fuel from spilling out if the bike goes down. The problem is that if it sticks or gets put on backwards it can severely damage the tank, so it's a tradeoff.

If you have the MC1000, your bike shipped without a hose on the FPR.

Maybe someone more familiar with the first gen bikes will chime in about the airbox hoses.

That's the classic scenario for fuel tank growth: full of ethanol gas outside in a warm place. The good news is that they do shrink back down.

Cheers,
-Kit
 
#7 · (Edited)
I'm just wrapping up a similar situation, though my fuel tank hasn't swelled. I have a 2001 Sprint ST 955i.

The #1 line is a fuel vent line that if you look down when the tank is lifted there is a small hole in a section of the frame which lines up with a wire holder just in front of the center stand pivot on the right hand side of the bike. Probably not a big problem if it's not there. I had to clean mine out as it was almost plugged.

I didn't have anything connected to #2.

The #4 line is the FPR (#3) vacuum line from the Air Box. I have no idea how critical the small amount of vacuum in the air box vs ambient air pressure would be. I think it is tapped behind the air filter, so may give a better representation of the air pressure available at the throttle body, ie. when filter is dirty. :shrug:

I also ended up with a fuel leak at the other coupling. I had to get a couple of O-rings from the dealer as they weren't in stock at my local Fastenal, but will order some back-ups.

Good luck with your tune-up.
 
#8 ·
#1 is actually the drain hose for the filler neck, in case you get water around the filler cap. It connects to a tiny hole to the left of the hole you put the gas nozzle into.

#2 is the fuel vent.

The line from the FPR to the airbox made little enough difference that Triumph stopped supplying it. I suspect #4 in the picture is the airbox drain hose, but it's hard to tell without seeing where it plugs into the airbox.

Cheers,
-Kit
 
#9 ·
Looking at the pictures and going off memory I am fairly positive #4 is the FPR hose. I would verify with my Sprint but it is currently 160 miles away in storage.:)
 
#10 ·
I'm having a hard time telling what size the #4 hose is in the pic. The airbox drain hose is a fair bit larger than the #1 and #2 hoses; the FPR hose is the same size as those. The drain hose should attach to the right rear of the airbox; the FPR hose, if present, should attach to the middle rear of the airbox.

Cheers,
-Kit
 
#11 · (Edited)
Kit, thanks for the clarification of line #1, that makes sense and explains why even though the line was plugged, it had little affect.

I definitely had a small line from the air box to the FPR and it's indicated in the 2001 ST/RS Service Manual. How important it is to have it hooked up I can't say. All I know is that's how it was hooked up before I took it apart. :wink2:

There were two larger and stiffer, drains on the air box (one on each side). The drain on the right connected just forward of the smaller vacuum (ambient air pressure) line that comes back to attach to the FPR.
 
#14 ·
Paul, your link only leads to a search table. However, if you are talking about the fuel quick-connect fittings, they are a well known and oft-discussed issue. Do a search for "BSPT" and you will find multiple threads on the topic.

Short version: Triumph used Colder plastic fittings. They are/were inferior quality. The recall replaced the male halves with aluminum bits. However, the really problematic bit is the female fitting that screws into the tank.

Solution is to buy the Colder metal fittings.

Hope this helps!

pr
 
#15 ·
Paul, your link only leads to a search table. However, if you are talking about the fuel quick-connect fittings, they are a well known and oft-discussed issue. Do a search for "BSPT" and you will find multiple threads on the topic.
Short version: Triumph used Colder plastic fittings. They are/were inferior quality. The recall replaced the male halves with aluminum bits. However, the really problematic bit is the female fitting that screws into the tank.
Solution is to buy the Colder metal fittings.
Hope this helps!
pr
Yes, you must insert the make & model in that recall link I put up, eg Triumph, RS Sprint, to get up the recalls itemised 1 -4, I should have explained. Then hover over the item 4 & it gives greater detail on the problem with the male fuel connectors. I had them changed on recall on my ST955 but like I said they fitted the wrong size, on the '99 models they were 8mm & 10mm, the dealer fitted both 10mm as on later models, which resulted in the one peeing out fuel.

I only mentioned this because in the OP's pic it looks like they are the old plastic type male connectors. So may not have had the recall.
 
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