B-026 . Fuel Filter Bracket Retrofit
Contents
1. B 026INT 5 of 52. frame or harness component If it does the hose could be damaged 21 Check that the 7 in 177 8 mm hose is not contacting any sharp engine frame or harness components 22 Fill fuel tank Turn ignition ON and listen for fuel pump activation 23 Start the vehicle and verify that it idles well and that there are no fuel leaks B 026INT CREDIT PROCEDURES After servicing each vehicle file a warranty claim referencing Service Bulletin B O26INT in the Description of Repair or Comments section of the claim Fill in the rest of the claim as follows Claim Type BMC BGW Event 1 Qty Problem Part No 0 62343 99Y Event 1 Additional Replacement Qty Problem Part No 1 91445 99Y S3 1 91436 99Y X1 Part Description Primary Labor Code Fuel Filter Upgrade Kit 3517 Time includes 0 2 administrative time hr 1 0 X1 Models 0 9 S3 S3T Models Customer Concern Code 9203 Condition Code 9102 Use BMC if vehicle is still within factory warranty period use BGW if vehicle is beyond factory warranty period Vehicles beyond factory warranty period do not require prior authoriza tion for this product program NOTE If additional parts such as cable straps are required list them under Event 1 Additional Parts After processing of the claim form you will be credited for the labor No credit will be issued for parts as they were sent no charge
3. Bracket Upgrade Kit Part No 91445 99Y NOTE The instructions that follow are the same as those provided in the instruction sheets J01748 and J01784 that came with the kits This bulletin is provided to address credit procedures for replacement of the fuel filter brackets Vehicles beyond the warranty period will not require a prior authorization See CREDIT PROCEDURES This X1 Fuel Filter Upgrade kit Part No 91436 99Y includes the following 1 Bracket Fuel Filter Support 4 Hose Clamps e 2 Wire Ties 1 Fuel Filter This S3 S3T Fuel Filter Upgrade kit Part No 91445 99Y includes the following 1 Bracket Fuel Filter Support 4 Hose Clamps 2 Wire Ties 1 Fuel Filter KIT INSTALLATION Lightning X1 Models NOTE Perform the following procedures according to the guidelines given in the service manual for the model being serviced To prevent accidental start up of vehicle and possible personal injury always disconnect the negative battery cable when working on a motorcycle If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 1 Disconnect negative battery cable from battery The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the syst
4. SERVICE BULLETIN Buell B 026INT October 6 1999 AMERICAN MOTORCYCLES FUEL FILTER BRACKET RETROFIT JAPAN ONLY GENERAL It has come to the attention of Buell Distribution Corporation that a certain number of 2000 Model X1 and S3 T model Buell motorcycles were shipped to the Japanese market with the incorrect fuel filter bracket This bracket must be replaced with the correct bracket before the motorcycle is sold Failure to replace the fuel filter bracket will affect the clearance between the fuel hose and the cooling fan and will affect the safe operation of the motorcycle The purpose of this service bulletin is to provide service instructions and to provide credit information on this procedure Motorcycles built after August 16 1999 will already have the new fuel filter bracket installed See below for VIN breakdown of vehicles that are not equipped with the new fuel filter bracket from the factory X1 World prior to VIN 4MZSS11J5Y3200619 3 S3T World prior to VIN 4MZFS11J2Y3100009 VEHICLES INVOLVED Select 2000 Model Year X1 and S3 S3T Models shipped to Harley Davidson Japan DEALER ACTION Replace the fuel filter bracket on all affected 2000 Model Year X1 and S3 S3T Models The following kits have been developed for replacement of the fuel filter bracket on the 1999 2000 model year Buell motorcycles indicated X1 Models Fuel Filter Bracket Upgrade Kit Part No 91436 99Y 3 S3T Models Fuel Filter
5. em of high pressure gas before removing fuel tank Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury CAUTION Use caution when removing fuel tank to avoid cosmetic damage to fuel tank cover 2 Purge the fuel line and remove the fuel tank See appro priate service manual Section 4 for procedures ROUTING SERVICE SALES PARTS LEAD TECHNICIAN TECHNICIAN TECHNICIAN TECHNICIAN RETURN MANAGER MANAGER MANAGER TECHNICIAN NO 1 NO 2 NO 3 NO 4 THIS TO INITIAL HERE 1999 Buell Distribution Corporation WARNING A small amount of gasoline will drain from the fuel line when the filter is removed Thoroughly wipe up any spilt fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 3 Remove fuel filter and fuel lines Discard filter and fuel lines but retain sheathing CAUTION Do not rotate fuel fitting by rotating the fitting nut Dam age to fuel pump connection may occur A See Figure 1 Rotate the fuel outlet approximately 180 by tightening the fuel outlet into the fuel fitting nut while securely holding the nut The fitting should point toward the rear of the motorcycle opposite of the way shown CAUTION Be sure to push the fuel line all the way onto the fuel rail connection Position hose clamp on s
6. n the clamp Ensure that it is not contacting any sharp engine frame or harness components 13 See Figure 4 Remove the rear cylinder head bolt and washer Discard washer 14 Install the fuel filter bracket onto the bolt Apply LOCTITE THREADLOCKER 262 red to the three bottom threads of the bolt 15 Reinstall the bolt into the cylinder head and torque to 30 33 ft lbs 40 7 44 7 Nm CAUTION Be sure to push the fuel line all the way onto the fuel fit ting Position hose clamp on straight section of fitting clear of barb and properly tighten the clamp 16 See Figure 5 Cut a piece of bulk fuel line Part No 63521 95 to 7 in 177 8 mm Attach the line to the fuel tank fuel outlet fitting with a hose clamp and tighten clamp 17 Prop fuel tank against frame Slide a hose clamp onto the 7 in 177 8 mm hose attach the hose to the filter s inlet fitting and tighten clamp Route hose as shown in Figure 5 18 Install fuel tank See appropriate service manual or recall 0814 for procedure 19 Reconnect the fuel pump See appropriate service man ual Section 4 for procedure After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation resulting in loss of control of vehicle and death or serious injury 20 Install seat and reconnect the negative battery cable CAUTION Ensure that the hose is not contacting any sharp engine
7. sten for fuel pump activation 18 Start vehicle and verify that it idles well and that there are no fuel leaks Thunderbolt S3 S3T Models Awarninc To prevent accidental startup of the motorcycle and pos sible personal injury always disconnect the negative battery cable when working on a motorcycle If the posi tive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 1 Disconnect negative battery cable Awarninc The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gasoline before removing fuel tank Gasoline is extremely flamma ble and highly explosive Inadequate safety precautions could result in death or serious injury 2 See the applicable Service Manual Purge the fuel line 3 Remove the seat NOTE The original fuel tank mounting parts for the S3 models were recalled campaign number 0814 If the new parts are not on your vehicle perform the recall together with this upgrade Per the recall the procedure for removing and installing the fuel tank has been modified Refer to the procedures in the recall bulletin instead of those in the Service Manual B 026INT Filter Arrow Direction 1 Rear Cylinder i Head Bolt F
8. ter and fuel lines but retain sheathing CAUTION Do not rotate fuel fitting by rotating the fitting nut Dam age to the fuel pump connection may occur o See Figure 1 Rotate the fuel outlet approximately 180 by tightening the fuel outlet into the fuel fitting nut while securely holding the nut The fitting should point toward the rear of the motorcycle opposite of the way shown CAUTION Be sure to push the fuel line all the way onto the fuel rail connection Position hose clamp on straight section of fitting clear of barb and properly tighten the clamp 10 See Figure 2 Cut a piece of bulk fuel line Part No 63521 95 to 10 1 2 in 266 7 mm Attach fuel line with a hose clamp to the fuel rail and tighten clamp Slide the sheathing onto the hose and route hose as shown 11 See Figure 6 Using the wire ties attach the fuel filter to the bracket with the filters ridge on the middle slot of the bracket Verify that the flow arrow on the filter is pointing towards front of vehicle 4of5 CAUTION Ensure that the hose is not contacting any sharp engine frame or harness component If it does the hose could be damaged Be sure to push the fuel line all the way onto the fuel fitting Position hose clamp on straight section of fit ting clear of barb and properly tighten the clamp 12 Slide a hose clamp on the 10 1 2 in 266 7 mm hose attach the discharge fitting of the filter onto the hose and tighte
9. traight section of fitting clear of barb and properly tighten the clamp 5 See Figure 2 Cut a piece of bulk fuel line Part No 63521 95 to 10 1 2 in 266 7 mm Attach fuel line with a hose clamp to the fuel rail and tighten clamp Slide the sheathing onto the hose and route hose as shown 6 See Figure 3 Using the wire ties attach the fuel filter to the bracket with the filter s ridge on the middle slot of the bracket Verify that the flow arrow on the filter is pointing towards front of vehicle CAUTION Ensure that the hose is not contacting any sharp engine frame or harness component If it does the hose could be damaged Be sure to push the fuel line all the way onto the fuel fitting Position hose clamp on straight section of fit ting clear of barb and properly tighten the clamp N Slide a hose clamp on the 10 1 2 in 266 7 mm hose attach the discharge fitting of the filter onto the hose and tighten the clamp Ensure that it is not contacting any sharp engine frame or harness components See Figure 4 Remove the rear cylinder head bolt and washer Discard washer Install the fuel filter and bracket onto the bolt Apply LOCTITE THREADLOCKER 262 red to the three bot tom threads of the bolt 10 Reinstall the bolt into the cylinder head and torque to 30 33 ft lbs 40 7 44 7 Nm CAUTION Be sure to push the fuel line all the way onto the fuel fit ting Position hose clamp on s
10. traight section of fitting clear of barb and properly tighten the clamp 2of5 a Fuel om ait Outlet eS Fuel Fitting Nut Figure 1 Fuel Outlet Fitting i01799 Fuel Line Sheathing Fuel Hose Bracket traight section of fitting Figure 3 Filter Mounted to Bracket X1 Shown B 026INT 11 See Figure 5 Cut a piece of bulk fuel line Part No 63521 95 to 7 in 177 8 mm Attach the line to the fuel tank fuel outlet fitting with a hose clamp and tighten clamp 12 Slide a hose clamp onto the 7 in 177 8 mm hose attach the hose to the filters inlet fitting and tighten clamp Route hose as shown in Figure 5 13 Install fuel tank See Section 4 of appropriate service manual for procedure 14 Reconnect the fuel pump See Section 4 of appropriate service manual for procedure WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation resulting in loss of control of vehicle and death or serious injury 15 Install seat and reconnect the negative battery cable CAUTION Ensure that the hose is not contacting any sharp engine frame or harness component If it does the hose could be damaged 16 Check that the 7 in 177 8 mm hose is not contacting any sharp engine frame or harness components 17 Fill fuel tank Turn ignition ON and li
11. uel Outlet h f Hose Clamp Jr CY IA Fuel Hose 7 in Figure 5 Fuel Tank to Filter u Fuel Hose 10 1 2 in 4 Figure 6 Filter Mounted to Bracket S3 Shown 3 0f 5 gt Remove bolt top mounting plate and top retention plate from fuel tank rear mount Lift tank and remove lower retention plate and lower mounting plate a Disconnect hose from vapor vent valve WARNING A small amount of gasoline will drain from the fuel sup ply fitting and fuel line when removed Thoroughly wipe up any spilled fuel immediately Dispose of rags in a suit able manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 6 Prop fuel tank against frame to gain access to fuel sup ply fitting Wrap shop towel around the fuel supply fitting and remove fuel line CAUTION Use caution when removing fuel tank If tank should con tact other chassis parts tank finish may be damaged 7 Remove fuel tank from frame WARNING A small amount of gasoline will drain from the fuel line when the filter is removed Thoroughly wipe up any spilled fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 8 See applicable Service Manual and remove the fuel filter and fuel lines Discard fil
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